Application Equipment Manual

FANUC Robotseries
Application Equipment
Manual
MARMCP7AP07071E REV C
©2013 FANUC America Corporation
This publication contains proprietary information

of FANUC America Corporation furnished for
customer use only. No other uses are authorized
without the express written permission of
FANUC America Corporation.
FANUC America Corporation

3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
If you have a controller labeled R-J3iC, you should read R-J3iC as R-30iA throughout this manual.
Copyrights and Trademarks

This new publication contains proprietary information of FANUC America Corporation furnished for customer use only. No other uses are authorized without the express written permission of FANUC America Corporation.
The descriptions and specifications contained in this manual were in effect at the time this manual was approved for printing. FANUC America Corporation, hereinafter referred to as FANUC, reserves the right to discontinue models
at any time or to change specifications or design without notice and without incurring obligations.
FANUC manuals present descriptions, specifications, drawings, schematics, bills of material, parts, connections and/or procedures for installing, disassembling, connecting, operating and programming FANUC products and/or
systems. Such systems consist of robots, extended axes, robot controllers, application software, the KAREL® programming language, INSIGHT® vision equipment, and special tools.
FANUC recommends that only persons who have been trained in one or more approved FANUC Training Course(s) be permitted to install, operate, use, perform procedures on, repair, and/or maintain FANUC products and/or
systems and their respective components. Approved training necessitates that the courses selected be relevant to the type of system installed and application performed at the customer site.
WARNING
This equipment generates, uses, and can radiate radiofrequency energy and if not installed and used in accordance with the instruction manual, may cause interference to radio
communications. As temporarily permitted by regulation, it has not been tested for compliance with the limits for Class A computing devices pursuant to subpart J of Part 15 of
FCC Rules, which are designed to provide reasonable protection against such interference. Operation of the equipment in a residential area is likely to cause interference, in
which case the user, at his own expense, will be required to take whatever measure may be required to correct the interference.
FANUC conducts courses on its systems and products on a regularly scheduled basis at the company's world headquarters in Rochester Hills, Michigan. For additional information contact
FANUC America Corporation
Training Department
3900 W. Hamlin Road
Rochester Hills, Michigan 48309-3253
www.fanucrobotics.com
For customer assistance, including Technical Support, Service, Parts & Part Repair, and Marketing Requests, contact the Customer Resource Center, 24 hours a day, at 1-800-47-ROBOT (1-800-477-6268). International customers
should call 011-1-248-377-7159.
Send your comments and suggestions about this manual to: product.documentation@fanucrobotics.com
Copyright © 2013 by FANUC America Corporation

All Rights Reserved
The information illustrated or contained herein is not to be

reproduced, copied, downloaded, translated into another language, published in any physical or electronic format, including internet, or transmitted in whole or in part in any way without the prior written consent of FANUC America
Corporation.
AccuStat®, ArcTool®, iRVision®, KAREL®, PaintTool®, PalletTool®, SOCKETS®, SpotTool®, SpotWorks®, and TorchMate® are Registered Trademarks of FANUC.
FANUC reserves all proprietary rights, including but not limited to trademark and trade name rights, in the following names:
AccuAir™, AccuCal™, AccuChop™, AccuFlow™, AccuPath™, AccuSeal™, ARC Mate™, ARC Mate Sr.™, ARC Mate System 1™, ARC Mate System 2™, ARC Mate System 3™, ARC Mate System 4™, ARC Mate System
5™, ARCWorks Pro™, AssistTool™, AutoNormal™, AutoTCP™, BellTool™, BODYWorks™, Cal Mate™, Cell Finder™, Center Finder™, Clean Wall™, DualARM™, LR Tool™, MIG Eye™, MotionParts™, MultiARM™,
NoBots™, Paint Stick™, PaintPro™, PaintTool 100™, PAINTWorks™, PAINTWorks II™, PAINTWorks III™, PalletMate™, PalletMate PC™, PalletTool PC™, PayloadID™, RecipTool™, RemovalTool™, Robo Chop™, Robo
Spray™, S-420i™, S-430i™, ShapeGen™, SoftFloat™, SOFT PARTS™, SpotTool+™, SR Mate™, SR ShotTool™, SureWeld™, SYSTEM R-J2 Controller™, SYSTEM R-J3 Controller™, SYSTEM R-J3iB Controller™,
SYSTEM R-J3iC Controller™, SYSTEM R-30iA Controller™, SYSTEM R-30iA Mate Controller™, SYSTEM R-30iB Controller™, SYSTEM R-30iB Mate Controller™, TCP Mate™, TorchMate™, TripleARM™, TurboMove™,
visLOC™, visPRO-3D™, visTRAC™, WebServer™, WebTP™, and YagTool™.
©FANUC CORPORATION 2013
 No part of this manual may be reproduced in any form.
 All specifications and designs are subject to change without notice.
Patents
One or more of the following U.S. patents might be related to the FANUC products described in this manual.
FANUC America Corporation Patent List

4,630,567 4,639,878 4,707,647 4,708,175 4,708,580 4,942,539 4,984,745 5,238,029 5,239,739 5,272,805 5,293,107 5,293,911 5,331,264 5,367,944 5,373,221 5,421,218 5,434,489 5,644,898 5,670,202 5,696,687 5,737,218 5,823,389
5,853,027 5,887,800 5,941,679 5,959,425 5,987,726 6,059,092 6,064,168 6,070,109 6,086,294 6,122,062 6,147,323 6,204,620 6,243,621 6,253,799 6,285,920 6,313,595 6,325,302 6,345,818 6,356,807 6,360,143 6,378,190 6,385,508
6,425,177 6,477,913 6,490,369 6,518,980 6,540,104 6,541,757 6,560,513 6,569,258 6,612,449 6,703,079 6,705,361 6,726,773 6,768,078 6,845,295 6,945,483 7,149,606 7,149,606 7,211,978 7,266,422 7,399,363
FANUC CORPORATION Patent List

4,571,694 4,626,756 4,700,118 4,706,001 4,728,872 4,732,526 4,742,207 4,835,362 4,894,596 4,899,095 4,920,248 4,931,617 4,934,504 4,956,594 4,967,125 4,969,109 4,970,370 4,970,448 4,979,127 5,004,968 5,006,035 5,008,834
5,063,281 5,066,847 5,066,902 5,093,552 5,107,716 5,111,019 5,130,515 5,136,223 5,151,608 5,170,109 5,189,351 5,267,483 5,274,360 5,292,066 5,300,868 5,304,906 5,313,563 5,319,443 5,325,467 5,327,057 5,329,469 5,333,242
5,337,148 5,371,452 5,375,480 5,418,441 5,432,316 5,440,213 5,442,155 5,444,612 5,449,875 5,451,850 5,461,478 5,463,297 5,467,003 5,471,312 5,479,078 5,485,389 5,485,552 5,486,679 5,489,758
5,493,192 5,504,766 5,511,007 5,520,062 5,528,013 5,532,924 5,548,194 5,552,687 5,558,196 5,561,742 5,570,187 5,570,190 5,572,103 5,581,167 5,582,750 5,587,635 5,600,759 5,608,299 5,608,618 5,624,588 5,630,955 5,637,969
5,639,204 5,641,415 5,650,078 5,658,121 5,668,628 5,687,295 5,691,615 5,698,121 5,708,342 5,715,375 5,719,479 5,727,132 5,742,138 5,742,144 5,748,854 5,749,058 5,760,560 5,773,950 5,783,922 5,799,135 5,812,408 5,841,257
5,845,053 5,872,894 5,887,122 5,911,892 5,912,540 5,920,678 5,937,143 5,980,082 5,983,744 5,987,591 5,988,850 6,023,044 6,032,086 6,040,554 6,059,169 6,088,628 6,097,169 6,114,824 6,124,693
6,140,788 6,141,863 6,157,155 6,160,324 6,163,124 6,177,650 6,180,898 6,181,096 6,188,194 6,208,105 6,212,444 6,219,583 6,226,181 6,236,011 6,236,896 6,250,174 6,278,902 6,279,413 6,285,921 6,298,283 6,321,139 6,324,443
6,328,523 6,330,493 6,340,875 6,356,671 6,377,869 6,382,012 6,384,371 6,396,030 6,414,711 6,424,883 6,431,018 6,434,448 6,445,979 6,459,958 6,463,358 6,484,067 6,486,629 6,507,165 6,654,666 6,665,588 6,680,461 6,696,810
6,728,417 6,763,284 6,772,493 6,845,296 6,853,881 6,888,089 6,898,486 6,917,837 6,928,337 6,965,091 6,970,802 7,038,165 7,069,808 7,084,900 7,092,791 7,133,747 7,143,100 7,149,602 7,131,848
7,161,321 7,171,041 7,174,234 7,173,213 7,177,722 7,177,439 7,181,294 7,181,313 7,280,687 7,283,661 7,291,806 7,299,713 7,315,650 7,324,873 7,328,083 7,330,777 7,333,879 7,355,725 7,359,817 7,373,220 7,376,488 7,386,367
7,464,623 7,447,615 7,445,260 7,474,939 7,486,816 7,495,192 7,501,778 7,502,504 7,508,155 7,512,459 7,525,273 7,526,121
Conventions
WARNING
Information appearing under the "WARNING" caption concerns the protection of
personnel. It is boxed and bolded to set it apart from the surrounding text.
CAUTION
Information appearing under the "CAUTION" caption concerns the protection of
equipment, software, and data. It is boxed and bolded to set it apart from the
surrounding text.
Note Information appearing next to NOTE concerns related information or useful hints
Safety
FANUC America Corporation is not and does not represent itself as an expert in safety systems, safety equipment, or the specific safety aspects of your company and/or its work force. It is the responsibility of the owner,
employer, or user to take all necessary steps to guarantee the safety of all personnel in the workplace.
The appropriate level of safety for your application and installation can be best determined by safety system professionals. FANUC AMERICA CORPORATION therefore, recommends that each customer consult with
such professionals in order to provide a workplace that allows for the safe application, use, and operation of FANUC AMERICA CORPORATION systems.
According to the industry standard ANSI/RIA R15-06, the owner or user is advised to consult the standards to ensure compliance with its requests for Robotics System design, usability, operation, maintenance, and service.
Additionally, as the owner, employer, or user of a robotic system, it is your responsibility to arrange for the training of the operator of a robot system to recognize and respond to known hazards associated with your robotic
system and to be aware of the recommended operating procedures for your particular application and robot installation.
Ensure that the robot being used is appropriate for the application. Robots used in classified (hazardous) locations must be certified for this use.
FANUC America Corporation therefore, recommends that all personnel who intend to operate, program, repair, or otherwise use the robotics system be trained in an approved FANUC AMERICA CORPORATION
training course and become familiar with the proper operation of the system. Persons responsible for programming the system–including the design, implementation, and debugging of application programs–must be
familiar with the recommended programming procedures for your application and robot installation.
The following guidelines are provided to emphasize the importance of safety in the workplace.
CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Safety is essential whenever robots are used. Keep in mind the following factors with regard to safety:
 The safety of people and equipment
 Use of safety enhancing devices
 Techniques for safe teaching and manual operation of the robot(s)
 Techniques for safe automatic operation of the robot(s)
 Regular scheduled inspection of the robot and workcell
 Proper maintenance of the robot
i
Safety
Keeping People Safe
The safety of people is always of primary importance in any situation. When applying safety measures to your robotic system, consider the following:
 External devices
 Robot(s)
 Tooling
 Workpiece
Using Safety Enhancing Devices
Always give appropriate attention to the work area that surrounds the robot. The safety of the work area can be enhanced by the installation of some or all of the following devices:
 Safety fences, barriers, or chains
 Light curtains
 Interlocks
 Pressure mats
 Floor markings
 Warning lights
 Mechanical stops
 EMERGENCY STOP buttons
 DEADMAN switches
Setting Up a Safe Workcell
A safe workcell is essential to protect people and equipment. Observe the following guidelines to ensure that the workcell is set up safely. These suggestions are intended to supplement and not replace existing federal,
state, and local laws, regulations, and guidelines that pertain to safety.
 Sponsor your personnel for training in approved FANUC AMERICA CORPORATION training course(s) related to your application. Never permit untrained personnel to operate the robots.
 Install a lockout device that uses an access code to prevent unauthorized persons from operating the robot.
 Use anti–tie–down logic to prevent the operator from bypassing safety measures.
 Arrange the workcell so the operator faces the workcell and can see what is going on inside the cell.
 Clearly identify the work envelope of each robot in the system with floor markings, signs, and special barriers. The work envelope is the area defined by the maximum motion range of the robot, including any tooling
attached to the wrist flange that extend this range.
 Position all controllers outside the robot work envelope.
 Never rely on software or firmware based controllers as the primary safety element unless they comply with applicable current robot safety standards.
 Mount an adequate number of EMERGENCY STOP buttons or switches within easy reach of the operator and at critical points inside and around the outside of the workcell.
 Install flashing lights and/or audible warning devices that activate whenever the robot is operating, that is, whenever power is applied to the servo drive system. Audible warning devices shall exceed the ambient noise
level at the end–use application.
 Wherever possible, install safety fences to protect against unauthorized entry by personnel into the work envelope.
 Install special guarding that prevents the operator from reaching into restricted areas of the work envelope.
 Use interlocks.
 Use presence or proximity sensing devices such as light curtains, mats, and capacitance and vision systems to enhance safety.
ii
Safety
 Periodically check the safety joints or safety clutches that can be optionally installed between the robot wrist flange and tooling. If the tooling strikes an object, these devices dislodge, remove power from the system,
and help to minimize damage to the tooling and robot.
 Make sure all external devices are properly filtered, grounded, shielded, and suppressed to prevent hazardous motion due to the effects of electro–magnetic interference (EMI), radio frequency interference (RFI), and
electro–static discharge (ESD).
 Make provisions for power lockout/tagout at the controller.
 Eliminate pinch points. Pinch points are areas where personnel could get trapped between a moving robot and other equipment.
 Provide enough room inside the workcell to permit personnel to teach the robot and perform maintenance safely.
 Program the robot to load and unload material safely.
 If high voltage electrostatics are present, be sure to provide appropriate interlocks, warning, and beacons.
 If materials are being applied at dangerously high pressure, provide electrical interlocks for lockout of material flow and pressure.
Staying Safe While Teaching or Manually Operating the Robot
Advise all personnel who must teach the robot or otherwise manually operate the robot to observe the following rules:
 Never wear watches, rings, neckties, scarves, or loose clothing that could get caught in moving machinery.
 Know whether or not you are using an intrinsically safe teach pendant if you are working in a hazardous environment.
 Before teaching, visually inspect the robot and work envelope to make sure that no potentially hazardous conditions exist. The work envelope is the area defined by the maximum motion range of the robot. These
include tooling attached to the wrist flange that extends this range.
 The area near the robot must be clean and free of oil, water, or debris. Immediately report unsafe working conditions to the supervisor or safety department.
 FANUC AMERICA CORPORATION recommends that no one enter the work envelope of a robot that is on, except for robot teaching operations. However, if you must enter the work envelope, be sure all safeguards
are in place, check the teach pendant DEADMAN switch for proper operation, and place the robot in teach mode. Take the teach pendant with you, turn it on, and be prepared to release the DEADMAN switch. Only
the person with the teach pendant should be in the work envelope.
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.
 Know the path that can be used to escape from a moving robot; make sure the escape path is never blocked.
 Isolate the robot from all remote control signals that can cause motion while data is being taught.
 Test any program being run for the first time in the following manner:
WARNING
Stay outside the robot work envelope whenever a program is being run. Failure to do
so can result in injury.
- Using a low motion speed, single step the program for at least one full cycle.
- Using a low motion speed, test run the program continuously for at least one full cycle.
iii
Safety
- Using the programmed speed, test run the program continuously for at least one full cycle.
 Make sure all personnel are outside the work envelope before running production.
Staying Safe During Automatic Operation
Advise all personnel who operate the robot during production to observe the following rules:
 Make sure all safety provisions are present and active.
 Know the entire workcell area. The workcell includes the robot and its work envelope, plus the area occupied by all external devices and other equipment with which the robot interacts.
 Understand the complete task the robot is programmed to perform before initiating automatic operation.
 Make sure all personnel are outside the work envelope before operating the robot.
 Never enter or allow others to enter the work envelope during automatic operation of the robot.
 Know the location and status of all switches, sensors, and control signals that could cause the robot to move.
 Know where the EMERGENCY STOP buttons are located on both the robot control and external control devices. Be prepared to press these buttons in an emergency.
 Never assume that a program is complete if the robot is not moving. The robot could be waiting for an input signal that will permit it to continue its activity.
 If the robot is running in a pattern, do not assume it will continue to run in the same pattern.
 Never try to stop the robot, or break its motion, with your body. The only way to stop robot motion immediately is to press an EMERGENCY STOP button located on the controller panel, teach pendant, or emergency
stop stations around the workcell.
Staying Safe During Inspection
When inspecting the robot, be sure to

 Turn off power at the controller.
 Lock out and tag out the power source at the controller according to the policies of your plant.
 Turn off the compressed air source and relieve the air pressure.
 If robot motion is not needed for inspecting the electrical circuits, press the EMERGENCY STOP button on the operator panel.
 If power is needed to check the robot motion or electrical circuits, be prepared to press the EMERGENCY STOP button, in an emergency.
 Be aware that when you remove a servomotor or brake, the associated robot arm will fall if it is not supported or resting on a hard stop. Support the arm on a solid support before you release the brake.
Staying Safe During Maintenance
When performing maintenance on your robot system, observe the following rules:
 Never enter the work envelope while the robot or a program is in operation.
 Before entering the work envelope, visually inspect the workcell to make sure no potentially hazardous conditions exist.
 Consider all or any overlapping work envelopes of adjoining robots when standing in a work envelope.
 Test the teach pendant for proper operation before entering the work envelope.
 If it is necessary for you to enter the robot work envelope while power is turned on, you must be sure that you are in control of the robot. Be sure to take the teach pendant with you, press the DEADMAN switch, and
turn the teach pendant on. Be prepared to release the DEADMAN switch to turn off servo power to the robot immediately.
 Whenever possible, perform maintenance with the power turned off. Before you open the controller front panel or enter the work envelope, turn off and lock out the 3–phase power source at the controller.
iv
Safety
WARNING
Lethal voltage is present in the controller WHENEVER IT IS CONNECTED to a
power source. Be extremely careful to avoid electrical shock. HIGH VOLTAGE IS
PRESENT at the input side whenever the controller is connected to a power
source. Turning the disconnect or circuit breaker to the OFF position removes
power from the output side of the device only.
 Release or block all stored energy. Before working on the pneumatic system, shut off the system air supply and purge the air lines.
 Isolate the robot from all remote control signals. If maintenance must be done when the power is on, make sure the person inside the work envelope has sole control of the robot. The teach pendant must be held by this
person.
 Make sure personnel cannot get trapped between the moving robot and other equipment. Know the path that can be used to escape from a moving robot. Make sure the escape route is never blocked.
 Use blocks, mechanical stops, and pins to prevent hazardous movement by the robot. Make sure that such devices do not create pinch points that could trap personnel.
WARNING
Do not try to remove any mechanical component from the robot before thoroughly
reading and understanding the procedures in the appropriate manual. Doing so can
result in serious personal injury and component destruction.
 When replacing or installing components, make sure dirt and debris do not enter the system.
 Use only specified parts for replacement. To avoid fires and damage to parts in the controller, never use nonspecified fuses.
 Before restarting a robot, make sure no one is inside the work envelope; be sure that the robot and all external devices are operating normally.
KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Certain programming and mechanical measures are useful in keeping the machine tools and other external devices safe. Some of these measures are outlined below. Make sure you know all associated measures for safe
use of such devices.
Programming Safety Precautions
Implement the following programming safety measures to prevent damage to machine tools and other external devices.
 Back–check limit switches in the workcell to make sure they do not fail.
 Implement ‘‘failure routines” in programs that will provide appropriate robot actions if an external device or another robot in the workcell fails.
 Use handshaking protocol to synchronize robot and external device operations.
 Program the robot to check the condition of all external devices during an operating cycle.
Mechanical Safety Precautions
Implement the following mechanical safety measures to prevent damage to machine tools and other external devices.
 Make sure the workcell is clean and free of oil, water, and debris.
 Use DCS (Dual Check Safety), software limits, limit switches, and mechanical hardstops to prevent undesired movement of the robot into the work area of machine tools and external devices.
v
Safety
KEEPING THE ROBOT SAFE

Observe the following operating and programming guidelines to prevent damage to the robot.
Operating Safety Precautions
The following measures are designed to prevent damage to the robot during operation.
 Use a low override speed to increase your control over the robot when jogging the robot.
 Visualize the movement the robot will make before you press the jog keys on the teach pendant.
 Make sure the work envelope is clean and free of oil, water, or debris.
 Use circuit breakers to guard against electrical overload.
Programming Safety Precautions
The following safety measures are designed to prevent damage to the robot during programming:
 Establish interference zones to prevent collisions when two or more robots share a work area.
 Make sure that the program ends with the robot near or at the home position.
 Be aware of signals or other operations that could trigger operation of tooling resulting in personal injury or equipment damage.
 In dispensing applications, be aware of all safety guidelines with respect to the dispensing materials.
NOTE: Any deviation from the methods and safety practices described in this manual must conform to the approved standards of your company. If you have questions, see your supervisor.
ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Process technicians are sometimes required to enter the paint booth, for example, during daily or routine calibration or while teaching new paths to a robot. Maintenance personnel also must work inside the paint booth
periodically.
Whenever personnel are working inside the paint booth, ventilation equipment must be used. Instruction on the proper use of ventilating equipment usually is provided by the paint shop supervisor.
Although paint booth hazards have been minimized, potential dangers still exist. Therefore, today’s highly automated paint booth requires that process and maintenance personnel have full awareness of the system and its
capabilities. They must understand the interaction that occurs between the vehicle moving along the conveyor and the robot(s), hood/deck and door opening devices, and high–voltage electrostatic tools.
CAUTION
Ensure that all ground cables remain connected. Never operate the paint robot with
ground provisions disconnected. Otherwise, you could injure personnel or damage
equipment.
Paint robots are operated in three modes:

 Teach or manual mode
 Automatic mode, including automatic and exercise operation
 Diagnostic mode
During both teach and automatic modes, the robots in the paint booth will follow a predetermined pattern of movements. In teach mode, the process technician teaches (programs) paint paths using the teach pendant.
In automatic mode, robot operation is initiated at the System Operator Console (SOC) or Manual Control Panel (MCP), if available, and can be monitored from outside the paint booth. All personnel must remain outside of
the booth or in a designated safe area within the booth whenever automatic mode is initiated at the SOC or MCP.
vi
Safety
In automatic mode, the robots will execute the path movements they were taught during teach mode, but generally at production speeds.
When process and maintenance personnel run diagnostic routines that require them to remain in the paint booth, they must stay in a designated safe area.
Paint System Safety Features
Process technicians and maintenance personnel must become totally familiar with the equipment and its capabilities. To minimize the risk of injury when working near robots and related equipment, personnel must comply
strictly with the procedures in the manuals.
This section provides information about the safety features that are included in the paint system and also explains the way the robot interacts with other equipment in the system.
The paint system includes the following safety features:

 Most paint booths have red warning beacons that illuminate when the robots are armed and ready to paint. Your booth might have other kinds of indicators. Learn what these are.
 Some paint booths have a blue beacon that, when illuminated, indicates that the electrostatic devices are enabled. Your booth might have other kinds of indicators. Learn what these are.
 EMERGENCY STOP buttons are located on the robot controller and teach pendant. Become familiar with the locations of all E–STOP buttons.
 An intrinsically safe teach pendant is used when teaching in hazardous paint atmospheres.
 A DEADMAN switch is located on each teach pendant. When this switch is held in, and the teach pendant is on, power is applied to the robot servo system. If the engaged DEADMAN switch is released or pressed
harder during robot operation, power is removed from the servo system, all axis brakes are applied, and the robot comes to an EMERGENCY STOP. Safety interlocks within the system might also E–STOP other
robots.
WARNING
An EMERGENCY STOP will occur if the DEADMAN switch is released on a bypassed
robot.
 Overtravel by robot axes is prevented by software limits. All of the major and minor axes are governed by software limits. DCS (Dual Check Safety), limit switches and hardstops also limit travel by the major axes.
 EMERGENCY STOP limit switches and photoelectric eyes might be part of your system. Limit switches, located on the entrance/exit doors of each booth, will EMERGENCY STOP all equipment in the booth if a
door is opened while the system is operating in automatic or manual mode. For some systems, signals to these switches are inactive when the switch on the SOC is in teach mode.
 When present, photoelectric eyes are sometimes used to monitor unauthorized intrusion through the entrance/exit silhouette openings.
 System status is monitored by computer. Severe conditions result in automatic system shutdown.
Staying Safe While Operating the Paint Robot
When you work in or near the paint booth, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING
Observe all safety rules and guidelines to avoid injury.
vii
Safety
WARNING
Never bypass, strap, or otherwise deactivate a safety device, such as a limit switch,
for any operational convenience. Deactivating a safety device is known to have
resulted in serious injury and death.
WARNING
Enclosures shall not be opened unless the area is known to be nonhazardous or
all power has been removed from devices within the enclosure. Power shall not be
restored after the enclosure has been opened until all combustible dusts have
been removed from the interior of the enclosure and the enclosure purged. Refer
to the Purge chapter for the required purge time.
 Know the work area of the entire paint station (workcell).

 Know the work envelope of the robot and hood/deck and door opening devices.
 Be aware of overlapping work envelopes of adjacent robots.
 Know where all red, mushroom–shaped EMERGENCY STOP buttons are located.
 Know the location and status of all switches, sensors, and/or control signals that might cause the robot, conveyor, and opening devices to move.
 Make sure that the work area near the robot is clean and free of water, oil, and debris. Report unsafe conditions to your supervisor.
 Become familiar with the complete task the robot will perform BEFORE starting automatic mode.
 Make sure all personnel are outside the paint booth before you turn on power to the robot servo system.
 Never enter the work envelope or paint booth before you turn off power to the robot servo system.
 Never enter the work envelope during automatic operation unless a safe area has been designated.
 Remove all metallic objects, such as rings, watches, and belts, before entering a booth when the electrostatic devices are enabled.
 Stay out of areas where you might get trapped between a moving robot, conveyor, or opening device and another object.
 Be aware of signals and/or operations that could result in the triggering of guns or bells.
 Be aware of all safety precautions when dispensing of paint is required.
 Follow the procedures described in this manual.
Special Precautions for Combustible Dusts (Powder Paint)

When the robot is used in a location where combustible dusts are found, such as the application of powder paint, the following special precautions are required to insure that there are no combustible dusts inside the robot.
 Purge maintenance air should be maintained at all times, even when the robot power is off. This will insure that dust can not enter the robot.
 A purge cycle will not remove accumulated dusts. Therefore, if the robot is exposed to dust when maintenance air is not present, it will be necessary to remove the covers and clean out any accumulated dust. Do not
energize the robot until you have performed the following steps.
1. Before covers are removed, the exterior of the robot should be cleaned to remove accumulated dust.
2. When cleaning and removing accumulated dust, either on the outside or inside of the robot, be sure to use methods appropriate for the type of dust that exists. Usually lint free rags dampened with water are acceptable.
Do not use a vacuum cleaner to remove dust as it can generate static electricity and cause an explosion unless special precautions are taken.
3. Thoroughly clean the interior of the robot with a lint free rag to remove any accumulated dust.
4. When the dust has been removed, the covers must be replaced immediately.
5. Immediately after the covers are replaced, run a complete purge cycle. The robot can now be energized.
viii
Safety
Staying Safe While Operating Paint Application Equipment

When you work with paint application equipment, observe the following rules, in addition to all rules for safe operation that apply to all robot systems.
WARNING
When working with electrostatic paint equipment, follow all national and local codes
as well as all safety guidelines within your organization. Also reference the
following standards: NFPA 33 Standards for Spray Application Using Flammable or
Combustible Materials, and NFPA 70 National Electrical Code.
 Grounding: All electrically conductive objects in the spray area must be grounded. This includes the spray booth, robots, conveyors, workstations, part carriers, hooks, paint pressure pots, as well as solvent containers.
Grounding is defined as the object or objects shall be electrically connected to ground with a resistance of not more than 1 megohms.
 High Voltage: High voltage should only be on during actual spray operations. Voltage should be off when the painting process is completed. Never leave high voltage on during a cap cleaning process.
 Avoid any accumulation of combustible vapors or coating matter.
 Follow all manufacturer recommended cleaning procedures.
 Make sure all interlocks are operational.
 No smoking.
 Post all warning signs regarding the electrostatic equipment and operation of electrostatic equipment according to NFPA 33 Standard for Spray Application Using Flammable or Combustible Material.
 Disable all air and paint pressure to bell.
 Verify that the lines are not under pressure.
Staying Safe During Maintenance
When you perform maintenance on the painter system, observe the following rules, and all other maintenance safety rules that apply to all robot installations. Only qualified, trained service or maintenance personnel
should perform repair work on a robot.
 Paint robots operate in a potentially explosive environment. Use caution when working with electric tools.
 When a maintenance technician is repairing or adjusting a robot, the work area is under the control of that technician. All personnel not participating in the maintenance must stay out of the area.
 For some maintenance procedures, station a second person at the control panel within reach of the EMERGENCY STOP button. This person must understand the robot and associated potential hazards.
 Be sure all covers and inspection plates are in good repair and in place.
 Always return the robot to the ‘‘home’’ position before you disarm it.
 Never use machine power to aid in removing any component from the robot.
 During robot operations, be aware of the robot’s movements. Excess vibration, unusual sounds, and so forth, can alert you to potential problems.
 Whenever possible, turn off the main electrical disconnect before you clean the robot.
 When using vinyl resin observe the following:
- Wear eye protection and protective gloves during application and removal.
- Adequate ventilation is required. Overexposure could cause drowsiness or skin and eye irritation.
- If there is contact with the skin, wash with water.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
 When using paint remover observe the following:
- Eye protection, protective rubber gloves, boots, and apron are required during booth cleaning.
- Adequate ventilation is required. Overexposure could cause drowsiness.
- If there is contact with the skin or eyes, rinse with water for at least 15 minutes. Then seek medical attention as soon as possible.
- Follow the Original Equipment Manufacturer’s Material Safety Data Sheets.
ix
TABLE OF CONTENTS MARMCP7AP07071E REV. C
TABLE OF CONTENTS
SAFETY.................................................................................................................................................................................................................................................................................................................................................i
TABLE OF CONTENTS .......................................................................................................................................................................................................................................................................................................................1
TABLE OF FIGURES .........................................................................................................................................................................................................................................................................................................................11
1 VERSABELL II+ APPLICATOR ..................................................................................................................................................................................................................................................................................................21
2 High Voltage Controls ...............................................................................................................................................................................................................................................................................................................23
2.1 Overview - ITW Ransburg High Voltage Control System........................................................................................................................................................................................................................................................................................23
2.1.1 Introduction..............................................................................................................................................................................................................................................................................................................................................................23
2.1.2 Specifications...........................................................................................................................................................................................................................................................................................................................................................23
2.1.2.1 Environmental / Physical ................................................................................................................................................................................................................................................................................................................................. 23 87H
2.1.2.2 UElectrical .......................................................................................................................................................................................................................................................................................................................................................... 23

8H 879H
2.1.3 Mounting Dimensions.............................................................................................................................................................................................................................................................................................................................................. 24

9H 80H
2.1.4 System Components................................................................................................................................................................................................................................................................................................................................................. 24

10H 81H
2.1.4.1 UDisplay ............................................................................................................................................................................................................................................................................................................................................................. 25

1H 82H
2.1.4.2 USwitches ........................................................................................................................................................................................................................................................................................................................................................... 25

12H 83H
2.1.4.3 ULED indicators ................................................................................................................................................................................................................................................................................................................................................. 26

13H 84H
2.1.4.4 UButtons ............................................................................................................................................................................................................................................................................................................................................................. 26

14H 85H
2.1.4.5 UConnections...................................................................................................................................................................................................................................................................................................................................................... 27
15H 86H
2.1.5 Cascades................................................................................................................................................................................................................................................................................................................................................................... 28
16H 87H
2.1.5.1 UHigh Voltage Cables ........................................................................................................................................................................................................................................................................................................................................ 29

17H 8H
2.1.6 Overview - ITW Ransburg High Voltage Control System ...................................................................................................................................................................................................................................................................................... 30

18H 89H
2.2
19H Operation and Setup – ITW HV Controller............................................................................................................................................................................................................................................................................................................... 30 890H
2.2.1 Start-Up Menu ......................................................................................................................................................................................................................................................................................................................................................... 30

20H 891H
2.2.2 Run Menu................................................................................................................................................................................................................................................................................................................................................................. 31

21H 892H
2.2.3 Mode Menu.............................................................................................................................................................................................................................................................................................................................................................. 31

2H 893H
2.2.4 Sensitivity Menu ...................................................................................................................................................................................................................................................................................................................................................... 31

23H 894H
2.2.5 Fault Menu ............................................................................................................................................................................................................................................................................................................................................................... 32

24H 895H
2.2.6 IP Address Menu...................................................................................................................................................................................................................................................................................................................................................... 32

25H 896H
2.2.7 Password Menu........................................................................................................................................................................................................................................................................................................................................................ 33

26H 897H
2.2.8 Enter new Password Menu....................................................................................................................................................................................................................................................................................................................................... 33

27H 89H
2.2.9 Parameters and Settings Menu................................................................................................................................................................................................................................................................................................................................. 33

28H 89H
2.2.9.1 UMode ................................................................................................................................................................................................................................................................................................................................................................ 33

29H 90H
2.2.9.2 UkVSet................................................................................................................................................................................................................................................................................................................................................................ 33
30H 901H
2.2.9.3 UuASet................................................................................................................................................................................................................................................................................................................................................................ 33
31H 902H
2.2.9.4 UkV Limit Hi ...................................................................................................................................................................................................................................................................................................................................................... 33

32H 903H
2.2.9.5 UuA Limit Hi ...................................................................................................................................................................................................................................................................................................................................................... 33

3H 904H
2.2.9.6 UDi/dt Sensitivity ............................................................................................................................................................................................................................................................................................................................................... 33

34H 905H
2.2.9.7 UDv/dt Sensitivity............................................................................................................................................................................................................................................................................................................................................... 33

35H 906H
2.2.9.8 UDx/Dt................................................................................................................................................................................................................................................................................................................................................................ 33
36H 907H
2.3
37H 16BControl Conditions – ITW HV Controller................................................................................................................................................................................................................................................................................................................. 34 908H
2.3.1 Power Up ................................................................................................................................................................................................................................................................................................................................................................. 34

38H 90H
2.3.2 HV On...................................................................................................................................................................................................................................................................................................................................................................... 34
39H 910H
2.3.3 Set Point Changed.................................................................................................................................................................................................................................................................................................................................................... 34

40H 91H
-1-
MARMCP7AP07071E REV. C TABLE OF CONTENTS
2.3.4 HV Off ..................................................................................................................................................................................................................................................................................................................................................................... 34

41H 912H
2.4
42H System Status (STS) – ITW HV Controller............................................................................................................................................................................................................................................................................................................... 34 913H
2.4.1 OK............................................................................................................................................................................................................................................................................................................................................................................ 34
43H 914H
2.4.2 Starting/Rising/Falling ............................................................................................................................................................................................................................................................................................................................................. 34

4H 915H
2.4.3 Running.................................................................................................................................................................................................................................................................................................................................................................... 34
45H 916H
2.4.4 Stopping ................................................................................................................................................................................................................................................................................................................................................................... 34

46H 917H
2.4.5 Warning.................................................................................................................................................................................................................................................................................................................................................................... 34
47H 918H
2.4.6 Fault ......................................................................................................................................................................................................................................................................................................................................................................... 34

48H 91H
2.5
49H System Check (CHK) – ITW HV Controller............................................................................................................................................................................................................................................................................................................. 35 920H
2.5.1 OK............................................................................................................................................................................................................................................................................................................................................................................ 35
50H 921H
2.5.2 NoGo........................................................................................................................................................................................................................................................................................................................................................................ 35
51H 92H
2.6
52H Ethernet I/P Interface – ITW HV Controller ............................................................................................................................................................................................................................................................................................................. 35 923H
2.6.1 Ethernet I/P Configuration ....................................................................................................................................................................................................................................................................................................................................... 35

53H 924H
2.6.1.1 UMAC ADDRESS: Unique hard coded by manufacturer, displayed on unit ................................................................................................................................................................................................................................................ 35
54H 925H
2.6.2 I/P Address Configuration ....................................................................................................................................................................................................................................................................................................................................... 35

5H 926H
2.6.3 Ethernet I/O.............................................................................................................................................................................................................................................................................................................................................................. 35

56H 927H
2.6.3.1 UOutput Words ................................................................................................................................................................................................................................................................................................................................................... 35

57H 928H
2.6.3.2 UOutput Bit Details ............................................................................................................................................................................................................................................................................................................................................ 36

58H 92H
2.6.3.3 UInput Words...................................................................................................................................................................................................................................................................................................................................................... 37

59H 930H
2.6.3.4 UInput Bit Details ............................................................................................................................................................................................................................................................................................................................................... 38

60H 931H
2.6.4 Ethernet I/O Parameter Configuration ..................................................................................................................................................................................................................................................................................................................... 39

61H 932H
2.6.4.1 UTO READ A PARAMETER: .......................................................................................................................................................................................................................................................................................................................... 39

62H 93H
2.6.4.2 UTO WRITE A PARAMETER:......................................................................................................................................................................................................................................................................................................................... 39

63H 934H
2.7
64H Manual Operation – ITW HV Controller .................................................................................................................................................................................................................................................................................................................. 40 935H
2.7.1 Front Panel Display.................................................................................................................................................................................................................................................................................................................................................. 40

65H 936H
2.7.2 Local Mode .............................................................................................................................................................................................................................................................................................................................................................. 40

6H 937H
2.8
67H Remote Operation – ITW HV Controller .................................................................................................................................................................................................................................................................................................................. 41 938H
2.8.1 Voltage Mode........................................................................................................................................................................................................................................................................................................................................................... 41

68H 93H
2.8.2 Current Mode ........................................................................................................................................................................................................................................................................................................................................................... 41

69H 940H
2.8.3 Fault Reset ............................................................................................................................................................................................................................................................................................................................................................... 41

70H 941H
2.9
71H Maintenance and Repair ............................................................................................................................................................................................................................................................................................................................................ 41 942H
2.9.1 Cautions and Warnings ............................................................................................................................................................................................................................................................................................................................................ 41

72H 943H
2.9.2 Replace ITW Controller........................................................................................................................................................................................................................................................................................................................................... 42

73H 94H
2.10
74H Troubleshooting ..................................................................................................................................................................................................................................................................................................................................................... 42 945H
2.10.1 Fault Descriptions .................................................................................................................................................................................................................................................................................................................................................. 42

75H 946H
2.10.2 Warning Descriptions ............................................................................................................................................................................................................................................................................................................................................ 42

76H 947H
2.10.3 PaintTool Alarm Codes.......................................................................................................................................................................................................................................................................................................................................... 43

7H 948H
2.11
78H Spare Parts ............................................................................................................................................................................................................................................................................................................................................................. 4494H
2.11.1 Spare Parts ............................................................................................................................................................................................................................................................................................................................................................. 44

79H 950H
2.12
80H Overview – High voltage Controller FB-200 HVU............................................................................................................................................................................................................................................................................................... 44 951H
2.12.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 44
81H 952H
2.12.2 Specifications ......................................................................................................................................................................................................................................................................................................................................................... 44

82H 953H
2.12.2.1 UEnvironmental / Physical ............................................................................................................................................................................................................................................................................................................................... 44

83H 954H
2.12.2.2 UElectrical ........................................................................................................................................................................................................................................................................................................................................................ 45

84H 95H
2.12.3 Mounting / Installation........................................................................................................................................................................................................................................................................................................................................... 45

85H 956H
2.12.4 System Components............................................................................................................................................................................................................................................................................................................................................... 46

86H 957H
-2-
2.12.5 Backplane Connections.......................................................................................................................................................................................................................................................................................................................................... 49

87H 958H
2.12.5.1 UMain ............................................................................................................................................................................................................................................................................................................................................................... 49

8H 95H
2.12.5.2 UGenerator........................................................................................................................................................................................................................................................................................................................................................ 50
89H 960H
2.12.5.3 UDigital Outputs ............................................................................................................................................................................................................................................................................................................................................... 50

90H 961H
2.12.5.4 UDigital Inputs.................................................................................................................................................................................................................................................................................................................................................. 51

91H 962H
2.12.5.5 UAnalog outputs ............................................................................................................................................................................................................................................................................................................................................... 52

92H 963H
2.12.5.6 UAnalog inputs ................................................................................................................................................................................................................................................................................................................................................. 53

93H 964H
2.12.5.7 USub-D 9 connectors ........................................................................................................................................................................................................................................................................................................................................ 53

94H 965H
2.12.5.8 UEthernet connection........................................................................................................................................................................................................................................................................................................................................ 53

95H 96H
2.12.6 Cascades................................................................................................................................................................................................................................................................................................................................................................. 53
96H 967H
2.12.7 High Voltage Cables .............................................................................................................................................................................................................................................................................................................................................. 54

97H 968H
2.13
98H Operation and Setup – High voltage Controller FB-200 HVU.............................................................................................................................................................................................................................................................................. 55 96H
2.13.1 Select Language ..................................................................................................................................................................................................................................................................................................................................................... 55

9H 970H
2.13.2 Parameter Edit Mode ............................................................................................................................................................................................................................................................................................................................................. 55

10H 971H
2.13.3 Setup ...................................................................................................................................................................................................................................................................................................................................................................... 55

10H 972H
2.13.4 Passwords............................................................................................................................................................................................................................................................................................................................................................... 56
102H 973H
2.13.5 Assigning Passwords.............................................................................................................................................................................................................................................................................................................................................. 56

103H 974H
2.13.6 Parameter Assignment ........................................................................................................................................................................................................................................................................................................................................... 57

104H 975H
2.13.7 Paintworks Parameter Access ................................................................................................................................................................................................................................................................................................................................ 57

105H 976H
2.13.8 Step Mode Settings ................................................................................................................................................................................................................................................................................................................................................ 57

106H 97H
2.13.9 Parameter Security ................................................................................................................................................................................................................................................................................................................................................. 58

107H 978H
2.13.10 Pre-warning.......................................................................................................................................................................................................................................................................................................................................................... 58
108H 97H
2.13.11 Release ................................................................................................................................................................................................................................................................................................................................................................. 58

109H 980H
2.13.12 Locking ................................................................................................................................................................................................................................................................................................................................................................ 59

10H 981H
2.13.13 Plant Safety .......................................................................................................................................................................................................................................................................................................................................................... 59

1H 982H
2.13.14 Capacity ............................................................................................................................................................................................................................................................................................................................................................... 59

12H 983H
2.13.15 Remaining Energy................................................................................................................................................................................................................................................................................................................................................ 59

13H 984H
2.13.16 Calculated momentum voltage............................................................................................................................................................................................................................................................................................................................. 60

14H 985H
2.13.17 Remaining Energy Time ...................................................................................................................................................................................................................................................................................................................................... 60

15H 986H
2.13.18 Safety check ......................................................................................................................................................................................................................................................................................................................................................... 60

16H 987H
2.13.19 Parameter Controller ............................................................................................................................................................................................................................................................................................................................................ 60

17H 98H
2.13.20 Default U kV........................................................................................................................................................................................................................................................................................................................................................ 61

18H 98H
2.13.21 Default I µA ......................................................................................................................................................................................................................................................................................................................................................... 61

19H 90H
2.13.22 Default Operation................................................................................................................................................................................................................................................................................................................................................. 61

120H 91H
2.13.23 Imax switch off .................................................................................................................................................................................................................................................................................................................................................... 61

12H 92H
2.13.24 Max. +di/dt µA/s.................................................................................................................................................................................................................................................................................................................................................. 62

12H 93H
2.13.25 +di/dt Check......................................................................................................................................................................................................................................................................................................................................................... 62

123H 94H
2.13.26 Max. -di/dt µA/s................................................................................................................................................................................................................................................................................................................................................... 62

124H 95H
2.13.27 -di/dt Check.......................................................................................................................................................................................................................................................................................................................................................... 62

125H 96H
2.13.28 Umin kV............................................................................................................................................................................................................................................................................................................................................................... 63

126H 97H
2.13.29 Umin switch off ................................................................................................................................................................................................................................................................................................................................................... 63

127H 98H
2.13.30 Max. +dU/dt µA/s ................................................................................................................................................................................................................................................................................................................................................ 63

128H 9H
2.13.31 +dU/dt Check ....................................................................................................................................................................................................................................................................................................................................................... 63

129H 10H
2.13.32 Max. -dU/dt µA/s ................................................................................................................................................................................................................................................................................................................................................. 64

130H 10H
2.13.33 -di/dt Check.......................................................................................................................................................................................................................................................................................................................................................... 64

13H 102H
2.13.34 U-Run-Up kV/s .................................................................................................................................................................................................................................................................................................................................................... 64

132H 103H
-3-
2.13.35 I-Run-Up µA/s ..................................................................................................................................................................................................................................................................................................................................................... 65

13H 104H
2.13.36 dX/dT Averages (For Display Only) ................................................................................................................................................................................................................................................................................................................... 65

134H 105H
2.13.37 Ana. Input Ch....................................................................................................................................................................................................................................................................................................................................................... 65

135H 106H
2.13.38 Act. I Output ........................................................................................................................................................................................................................................................................................................................................................ 65

136H 107H
2.13.39 Max-I load % (only software 1.21f or higher) ..................................................................................................................................................................................................................................................................................................... 65

137H 108H
2.13.40 Count I load (only software 1.23f to 1.23Fc)....................................................................................................................................................................................................................................................................................................... 65

138H 109H
2.13.41 I load Time Out (only software 1.23Fe)............................................................................................................................................................................................................................................................................................................... 66

139H 10H
2.13.42 I-max off (only software 1.23f or higher) ............................................................................................................................................................................................................................................................................................................ 66

140H 10H
2.14 14H Default Parameters – High voltage Controller – FB-200 HVU............................................................................................................................................................................................................................................................................. 66 102H
2.15 142HManual Operation – High voltage Controller – FB-200 HVU .............................................................................................................................................................................................................................................................................. 68 103H
2.15.1 Local Mode ............................................................................................................................................................................................................................................................................................................................................................ 68

143H 104H
2.15.1.1 UStep X............................................................................................................................................................................................................................................................................................................................................................. 68

14H 105H
2.15.1.2 U Activate HV in local mode............................................................................................................................................................................................................................................................................................................................ 69

145H 106H
2.15.1.3 UStep selecting in local mode........................................................................................................................................................................................................................................................................................................................... 69

146H 107H
2.16 147HRemote mode – High voltage Controller FB-200 HVU ........................................................................................................................................................................................................................................................................................ 70 108H
2.16.1 Step selection ......................................................................................................................................................................................................................................................................................................................................................... 70

148H 109H
2.16.2 Selecting the operating mode in step 0 .................................................................................................................................................................................................................................................................................................................. 70

149H 102H
2.16.3 Activate high voltage in remote mode. .................................................................................................................................................................................................................................................................................................................. 70

150H 102H
2.16.4 Start safety check in remote mode. ........................................................................................................................................................................................................................................................................................................................ 70

15H 102H
2.17 152HMaintenance and Repair – High voltage Controller FB-200 HVU........................................................................................................................................................................................................................................................................ 70 1023H
2.17.1 HV Cable Installation............................................................................................................................................................................................................................................................................................................................................. 70

153H 1024H
2.17.1.1 UHV Cable Installation Procedure.................................................................................................................................................................................................................................................................................................................... 71

154H 1025H
2.17.2 Legacy Cascade Maintenance - Greasing Procedure ............................................................................................................................................................................................................................................................................................. 78

15H 1026H
2.17.3 Integrated Cascade Maintenance ........................................................................................................................................................................................................................................................................................................................... 80

156H 1027H
2.18 157HTroubleshooting – High voltage Controller FB-200 HVU .................................................................................................................................................................................................................................................................................... 80 1028H
2.18.1 HV Control Unit Alarms........................................................................................................................................................................................................................................................................................................................................ 80

158H 1029H
2.18.1.1 USwitched-Off because of CABLE-BREAK ................................................................................................................................................................................................................................................................................................... 81

159H 103H
2.18.1.2 USwitched-Off because of dV/dt-FAULT........................................................................................................................................................................................................................................................................................................ 81

160H 103H
2.18.1.3 USwitched-Off because of dI/dt-FAULT ......................................................................................................................................................................................................................................................................................................... 82

16H 1032H
2.18.1.4 USwitched-Off because of EXCEEDING POWER DISSIPATION................................................................................................................................................................................................................................................................ 83

162H 103H
2.18.1.5 USwitched-Off because of OVERLOAD (Vmin) ............................................................................................................................................................................................................................................................................................ 83

163H 1034H
2.18.1.6 USwitched-Off because of OVERLOAD (Imax) ............................................................................................................................................................................................................................................................................................. 84

164H 1035H
2.18.2 PaintTool HV Alarms ............................................................................................................................................................................................................................................................................................................................................ 84

165H 1036H
2.18.2.1 UPAIN-351 "Estat controller warning" ............................................................................................................................................................................................................................................................................................................ 84

16H 1037H
2.18.2.2 UPAIN-352 "Estat controller fault" .................................................................................................................................................................................................................................................................................................................. 85

167H 1038H
2.18.2.3 UPAIN-353 "Estats disabled" ........................................................................................................................................................................................................................................................................................................................... 85

168H 1039H
2.18.2.4 UPAIN-354 "Estat controller not in remote" .................................................................................................................................................................................................................................................................................................... 85

169H 104H
2.18.2.5 UPAIN-355 "Estat HVON Failed" ................................................................................................................................................................................................................................................................................................................... 85

170H 104H
2.18.2.6 UPAIN-356 "Estat set point not reached"*....................................................................................................................................................................................................................................................................................................... 85

17H 1042H
2.19 172HSpare Parts – High voltage Controller FB-200 HVU............................................................................................................................................................................................................................................................................................. 86 1043H
2.19.1 Spare Parts ............................................................................................................................................................................................................................................................................................................................................................. 86

173H 104H
3 Bell Speed Control System ....................................................................................................................................................................................................................................................................................................... 87

174H 1045H
3.1 Overview ................................................................................................................................................................................................................................................................................................................................................................... 87

175H 1046H
3.1.1 Introduction.............................................................................................................................................................................................................................................................................................................................................................. 87
176H 1047H
3.1.2 System Components – Block Diagram Overview ................................................................................................................................................................................................................................................................................................... 88

17H 1048H
3.2 Operation and Setup .................................................................................................................................................................................................................................................................................................................................................. 96

178H 1049H
-4-
3.2.1 Pressure Regulator (I/P) ........................................................................................................................................................................................................................................................................................................................................... 96

179H 105H
3.2.1.1 U Installation...................................................................................................................................................................................................................................................................................................................................................... 96
180H 105H
3.2.2 Fiber Optic Sensor (O/E) ......................................................................................................................................................................................................................................................................................................................................... 97

18H 1052H
3.2.2.1 U Installation...................................................................................................................................................................................................................................................................................................................................................... 98
182H 1053H
3.2.2.2 U Setup............................................................................................................................................................................................................................................................................................................................................................... 99
183H 1054H
3.2.2.3 UPreset Valve Programming............................................................................................................................................................................................................................................................................................................................... 99

184H 105H
3.2.3 Frequency Converter (F/I) ..................................................................................................................................................................................................................................................................................................................................... 100

185H 1056H
3.2.3.1 Installation....................................................................................................................................................................................................................................................................................................................................................... 100

186H 1057H
3.2.4 Turbine................................................................................................................................................................................................................................................................................................................................................................... 101

187H 1058H
3.2.5 Fiber Optic Cable ................................................................................................................................................................................................................................................................................................................................................... 102

18H 1059H
3.2.6 Software Setup ....................................................................................................................................................................................................................................................................................................................................................... 104

189H 106H
3.3 Troubleshooting....................................................................................................................................................................................................................................................................................................................................................... 105

190H 106H
3.3.1 Eq1: PNT1-701 PAUS %sMax. output has speed < setpoint ................................................................................................................................................................................................................................................................................ 105
19H 1062H
3.3.2 Eq1: PNT1-702 WARN %sRequested speed over valid range.............................................................................................................................................................................................................................................................................. 105
192H 1063H
3.3.3 Eq1: PNT1-703 WARN %sFailed to reach setpoint.............................................................................................................................................................................................................................................................................................. 106

193H 1064H
3.3.4 Eq1: PNT1-704 PAUS %sZero turbine speed timeout .......................................................................................................................................................................................................................................................................................... 106
194H 1065H
3.3.5 Eq1: PNT1-705 PAUS %sTurbine over speed ...................................................................................................................................................................................................................................................................................................... 107

195H 106H
3.3.6 Eq1: PNT1-706 PAUS %sTurbine under speed fault ............................................................................................................................................................................................................................................................................................ 107
196H 1067H
3.3.7 Eq1: PNT1-707 WARN %sTurbine under speed warning .................................................................................................................................................................................................................................................................................... 108
197H 1068H
3.3.8 Eq1: PNT1-708 WARN %sSpeed avg. error excessive......................................................................................................................................................................................................................................................................................... 108

198H 1069H
3.3.9 Eq1: PNT1-709 PAUS %sBearing Air NOT OK .................................................................................................................................................................................................................................................................................................. 108

19H 107H
3.3.10 Eq1: PNT1-710 WARN %sCruise Speed not established ................................................................................................................................................................................................................................................................................... 108
20H 107H
3.3.11 Eq1:PNT1-716 WARN %sTurbine Startup Test Not Complete.......................................................................................................................................................................................................................................................................... 109

201H 1072H
3.3.12 Eq1: PNT1-717 PAUS %sMax.dV/dT detected .................................................................................................................................................................................................................................................................................................. 109

20H 1073H
3.3.13 Eq2: PNT1-718 PAUS %sMax. output has speed < setpoint .............................................................................................................................................................................................................................................................................. 109
203H 1074H
3.3.14 Eq2: PNT1-719 WARN %sRequested speed over valid range............................................................................................................................................................................................................................................................................ 109
204H 1075H
3.3.15 Eq2: PNT1-720 WARN %sFailed to reach setpoint............................................................................................................................................................................................................................................................................................ 110

205H 1076H
3.3.16 Eq2: PNT1-721 PAUS %sZero turbine speed timeout ........................................................................................................................................................................................................................................................................................ 110
206H 107H
3.3.17 Eq2: PNT1-722 PAUS %sTurbine over speed .................................................................................................................................................................................................................................................................................................... 111

207H 1078H
3.3.18 Eq2: PNT1-723 PAUS %sTurbine under speed fault .......................................................................................................................................................................................................................................................................................... 112
208H 1079H
3.3.19 Eq2: PNT1-724 WARN %sTurbine under speed warning .................................................................................................................................................................................................................................................................................. 112
209H 108H
3.3.20 Eq2: PNT1-725 WARN %sSpeed avg. error excessive....................................................................................................................................................................................................................................................................................... 112

210H 108H
3.3.21 Eq2: PNT1-726 PAUS %sBearing Air NOT OK ................................................................................................................................................................................................................................................................................................ 113

21H 1082H
3.3.22 Eq2: PNT1-727 WARN %sCruise Speed not established ................................................................................................................................................................................................................................................................................... 113
21H 1083H
3.4 Troubleshooting Procedure...................................................................................................................................................................................................................................................................................................................................... 114

213H 1084H
3.4.1 Keyence optical feedback test:............................................................................................................................................................................................................................................................................................................................... 114

214H 1085H
3.4.2 Bell speed feedback troubleshooting procedure. ................................................................................................................................................................................................................................................................................................... 114

215H 1086H
3.5 Spare Parts & Tools ................................................................................................................................................................................................................................................................................................................................................. 119

216H 1087H
3.5.1 Spare Parts Required.............................................................................................................................................................................................................................................................................................................................................. 119

217H 108H
3.5.2 Tools Required....................................................................................................................................................................................................................................................................................................................................................... 120

218H 1089H
4 Bearing Air control................................................................................................................................................................................................................................................................................................................... 123

219H 109H
4.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 123

20H 109H
4.1.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 123

21H 1092H

2H 1093H
4.2 Operations and Setup............................................................................................................................................................................................................................................................................................................................................... 123

23H 1094H
4.2.1 Manual regulator at supply panel........................................................................................................................................................................................................................................................................................................................... 124

24H 1095H
-5-
4.2.2 Accumulator Tanks ................................................................................................................................................................................................................................................................................................................................................ 124

25H 1096H
4.2.3 Bearing Air P/I....................................................................................................................................................................................................................................................................................................................................................... 125

26H 1097H
4.3 Maintenance and Repair .......................................................................................................................................................................................................................................................................................................................................... 125

27H 1098H

28H 109H
4.4.1 PNT1-709 PAUS %sBearing Air NOT OK........................................................................................................................................................................................................................................................................................................... 125

29H 10H
5 Shape Air Control System - D/Q ............................................................................................................................................................................................................................................................................................. 127

230H 10H
5.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 127

231H 102H
5.1.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 127

23H 103H

23H 104H
5.2 Operation and Setup ................................................................................................................................................................................................................................................................................................................................................ 128

234H 105H
5.2.1 D/Q Air Flow Control Valve ................................................................................................................................................................................................................................................................................................................................. 128

235H 106H
5.2.2 P/I (analog output pressure gage)........................................................................................................................................................................................................................................................................................................................... 129

236H 107H
5.2.3 Software Setup ....................................................................................................................................................................................................................................................................................................................................................... 130

237H 108H
5.2.3.1 UD/Q Air Control Valve Calibration ................................................................................................................................................................................................................................................................................................................ 130

238H 109H
5.2.3.2 Shape Air Sense Calibration ........................................................................................................................................................................................................................................................................................................................... 131

239H 10H
5.2.3.3 UShape Air Control System Parameters ........................................................................................................................................................................................................................................................................................................... 133

240H 1H

241H 12H
5.3.1 Cautions & Warnings............................................................................................................................................................................................................................................................................................................................................. 134

24H 13H
5.3.2 D/Q Valve Cleaning Procedure.............................................................................................................................................................................................................................................................................................................................. 136

243H 14H
5.3.3 D/Q Valve Spare Parts Replacement Procedure .................................................................................................................................................................................................................................................................................................... 139

24H 15H
5.3.3.1 UReplacing Lower Valve Block O-Rings......................................................................................................................................................................................................................................................................................................... 139

245H 16H
5.3.3.2 UReplacing Upper Valve Block O-Rings ......................................................................................................................................................................................................................................................................................................... 140

246H 17H
5.3.3.3 UReplacing the Pipe Plug and Orifice .............................................................................................................................................................................................................................................................................................................. 143

247H 18H
5.3.3.4 Replacing the D/Q Cup Seals.......................................................................................................................................................................................................................................................................................................................... 144

248H 19H
5.3.4 Pressure Sensor (P/I).............................................................................................................................................................................................................................................................................................................................................. 146

249H 120H

250H 12H
5.4.1 PNT1-845 WARN 1 / PNT1-861 WARN 2 “Manifold Press low warning”......................................................................................................................................................................................................................................................... 146
251H 12H
5.4.1.1 UCause: Uncalibrated Shape Air Sense ............................................................................................................................................................................................................................................................................................................ 146

25H 123H
5.4.1.2 UCause: Air Leak due to Loose Applicator ...................................................................................................................................................................................................................................................................................................... 146

253H 124H
5.4.1.3 UCause: Air Leak due to Missing O-ring in Applicator ................................................................................................................................................................................................................................................................................... 146
254H 125H
5.4.1.4 UCause: Air Leak due to Missing O-ring in Shape Air Nozzle........................................................................................................................................................................................................................................................................ 146
25H 126H
5.4.1.5 UCause: Air Leak due to Loose line in Push-Lock Fitting ............................................................................................................................................................................................................................................................................... 147
256H 127H
5.4.1.6 UCause: Air Leak due to Damaged Hose ......................................................................................................................................................................................................................................................................................................... 147

257H 128H
5.4.1.7 UCause: Supply Pressure Fluctuation............................................................................................................................................................................................................................................................................................................... 147

258H 129H
5.4.1.8 PNT1-846 WARN 1 / PNT1-862 WARN 2 “Manifold Press high warning”................................................................................................................................................................................................................................................. 147
259H 130H
5.4.1.9 UCause: Uncalibrated Shape Air Sense ............................................................................................................................................................................................................................................................................................................ 147

260H 13H
5.4.1.10 UCause: Plugged Shape Air Nozzle Holes ..................................................................................................................................................................................................................................................................................................... 147

261H 132H
5.4.1.11 UCause: Supply Pressure Fluctuation ............................................................................................................................................................................................................................................................................................................. 147

26H 13H
5.4.1.12 PNT1-849 PAUS 1 / PNT1-865 PAUS 2 “Manifold Press low alarm”........................................................................................................................................................................................................................................................ 147
263H 134H
5.4.1.13 UCause: Uncalibrated Shape Air Sense .......................................................................................................................................................................................................................................................................................................... 148

264H 135H
5.4.1.14 UCause: Missing Shape Air Nozzle................................................................................................................................................................................................................................................................................................................ 148

265H 136H
5.4.1.15 UCause: Air Leak due to Loose Applicator .................................................................................................................................................................................................................................................................................................... 148

26H 137H
5.4.1.16 UCause: Air Leak due to Missing O-ring in Applicator ................................................................................................................................................................................................................................................................................. 148
267H 138H
5.4.1.17 UCause: Air Leak due to Missing O-ring in Shape Air Nozzle...................................................................................................................................................................................................................................................................... 148
268H 139H
5.4.1.18 UCause: Air Leak due to Loose line in Push-Lock Fitting ............................................................................................................................................................................................................................................................................. 148
269H 140H
5.4.1.19 UCause: Air Leak due to Damaged Hose ....................................................................................................................................................................................................................................................................................................... 148

270H 14H
-6-

271H 142H
5.4.1.21 PNT1-850 PAUS 1 / PNT1-866 PAUS 2 “Manifold Press high alarm”....................................................................................................................................................................................................................................................... 149
27H 143H
5.4.1.22 UCause: Uncalibrated Shape Air Sense .......................................................................................................................................................................................................................................................................................................... 149

273H 14H
5.4.1.23 UCause: Plugged Shape Air Nozzle Holes ..................................................................................................................................................................................................................................................................................................... 149

274H 145H

275H 146H
5.4.1.25 PNT1-851 PAUS 1 / PNT1-867 WARN 2 “Calibration successful”............................................................................................................................................................................................................................................................ 149

276H 147H
5.4.1.26 PNT1-852 PAUS 1 / PNT1-868 WARN 2 “Calibration aborted” ................................................................................................................................................................................................................................................................ 149

27H 148H
5.4.1.27 UCause: Robot mode of operation incorrect................................................................................................................................................................................................................................................................................................... 149

278H 149H
5.4.1.28 UCause: Calibration interrupted by another fault ........................................................................................................................................................................................................................................................................................... 149

279H 150H
5.4.1.29 PNT1-853 PAUS 1 / PNT1-869 WARN 2 “Non-incr cal table” .................................................................................................................................................................................................................................................................. 149
280H 15H
5.4.1.30 UCause: Air supply regulator set incorrectly.................................................................................................................................................................................................................................................................................................. 149

281H 152H
5.4.1.31 UCause: Loose line in Push-Lock Fitting ....................................................................................................................................................................................................................................................................................................... 150

28H 153H
5.4.1.32 UCause: Damaged Hose ................................................................................................................................................................................................................................................................................................................................. 150

283H 154H
5.4.1.33 PNT1-854 PAUS 1 / PNT1-870 WARN 2 “Zero Pressure”......................................................................................................................................................................................................................................................................... 150

284H 15H
5.4.1.34 UCause: Air supply regulator set incorrectly.................................................................................................................................................................................................................................................................................................. 150

285H 156H
5.4.1.35 UCause: Disconnected line in Push-Lock Fitting ........................................................................................................................................................................................................................................................................................... 150

286H 157H
5.4.1.36 UCause: Damaged Hose ................................................................................................................................................................................................................................................................................................................................. 150

287H 158H
5.4.1.37 UCause: Leak in Shape Air Sense line ........................................................................................................................................................................................................................................................................................................... 151

28H 159H
5.4.1.38 UCause: Missing Shape Air Nozzle................................................................................................................................................................................................................................................................................................................ 151

289H 160H
5.4.1.39 UCause: Air Leak due to Loose Applicator .................................................................................................................................................................................................................................................................................................... 151

290H 16H
5.4.1.40 UCause: Air Leak due to Missing O-ring in Applicator ................................................................................................................................................................................................................................................................................. 151
291H 162H
5.4.1.41 UCause: Air Leak due to Missing O-ring in Shape Air Nozzle...................................................................................................................................................................................................................................................................... 151
29H 163H
5.5 Spare Parts & Tools ................................................................................................................................................................................................................................................................................................................................................. 151

293H 164H

294H 165H
5.5.2 Tools Required....................................................................................................................................................................................................................................................................................................................................................... 152

295H 16H
6 Shape Air Control System - AccuAir...................................................................................................................................................................................................................................................................................... 155

296H 167H
6.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 155

297H 168H
6.1.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 155

298H 169H

29H 170H
6.1.2.1 Single Shape Air - AccuAir ............................................................................................................................................................................................................................................................................................................................ 155

30H 17H
6.1.2.2 Dual Shape Air – AccuAir .............................................................................................................................................................................................................................................................................................................................. 156

301H 172H

302H 173H
6.2.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 156

30H 174H

304H 175H
6.3.1 EX600 .................................................................................................................................................................................................................................................................................................................................................................... 157

305H 176H
6.3.2 Flow Meter............................................................................................................................................................................................................................................................................................................................................................. 157

306H 17H
6.3.3 Pressure Transducer ............................................................................................................................................................................................................................................................................................................................................... 158

307H 178H
6.3.4 Software Setup ....................................................................................................................................................................................................................................................................................................................................................... 160

308H 179H
6.3.4.1 UShape Air Calibration..................................................................................................................................................................................................................................................................................................................................... 160

309H 180H

310H 18H
6.4.1 Eq1: PNT1-616 WARN %sCalibration successful................................................................................................................................................................................................................................................................................................ 160

31H 182H
6.4.2 Eq1: PNT1-617 WARN %sCalibration aborted .................................................................................................................................................................................................................................................................................................... 160

312H 183H
6.4.3 Eq1: PNT1-618 WARN %sCal. low flow rate reset.............................................................................................................................................................................................................................................................................................. 161
31H 184H
6.4.4 Eq1: PNT1-619 WARN %sCal. max. flow rate reset ............................................................................................................................................................................................................................................................................................ 161
314H 185H
6.4.5 Eq2: PNT1-647 WARN %sCalibration successful................................................................................................................................................................................................................................................................................................ 161

315H 186H
6.4.6 Eq2: PNT1-648 WARN %sCalibration aborted .................................................................................................................................................................................................................................................................................................... 161

316H 187H
-7-
6.4.7 Eq2: PNT1-649 WARN %sCal. low flow rate reset.............................................................................................................................................................................................................................................................................................. 161
317H 18H
6.4.8 Eq2: PNT1-650 WARN %sCal. max. flow rate reset ............................................................................................................................................................................................................................................................................................ 162
318H 189H
6.4.9 Eq1: PNT1-626 WARN %sMax. output has flow < setpoint ................................................................................................................................................................................................................................................................................ 162
319H 190H
6.4.10 Eq1: PNT1-632 WARN %s0 air flow rate timeout ............................................................................................................................................................................................................................................................................................. 162
320H 19H
6.4.11 Eq2: PNT1-657 WARN %sMax. output has flow < setpoint .............................................................................................................................................................................................................................................................................. 163
321H 192H
6.4.12 Eq2: PNT1-663 WARN %s0 air flow rate timeout ............................................................................................................................................................................................................................................................................................. 163
32H 193H
7 Seal Air control......................................................................................................................................................................................................................................................................................................................... 165

32H 194H
7.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 165

324H 195H

325H 196H

326H 197H

327H 198H
7.5 Spare Parts and Tools .............................................................................................................................................................................................................................................................................................................................................. 166

328H 19H
8 IPC Paint delivery system ....................................................................................................................................................................................................................................................................................................... 169

329H 120H
8.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 169

30H 120H

31H 120H
8.2.1 Schematics ............................................................................................................................................................................................................................................................................................................................................................. 174

32H 1203H
8.2.2 1K Pump Manifold Block ...................................................................................................................................................................................................................................................................................................................................... 291

3H 1204H
8.2.3 Pump QD ............................................................................................................................................................................................................................................................................................................................................................... 293

34H 1205H
8.2.4 FRA Fast-Flush Regulator ..................................................................................................................................................................................................................................................................................................................................... 295

35H 1206H
8.2.5 Gear Pump ............................................................................................................................................................................................................................................................................................................................................................. 295

36H 1207H
8.2.6 2K Specific Hardware............................................................................................................................................................................................................................................................................................................................................ 307

37H 1208H

38H 1209H

39H 120H
8.4.1 Eq1: PNT1-733 WARN %sPump 1 IN low pressure warning .............................................................................................................................................................................................................................................................................. 337
340H 12H
8.4.2 Eq1: PNT1-734 PAUS %sPump 1 IN low pressure fault ...................................................................................................................................................................................................................................................................................... 337
341H 12H
8.4.3 Eq1: PNT1-735 WARN %sPump 1 IN high pressure warning ............................................................................................................................................................................................................................................................................. 338
342H 123H
8.4.4 Eq1: PNT1-736 PAUS %sPump 1 IN high pressure fault ..................................................................................................................................................................................................................................................................................... 338
34H 124H
8.4.5 Eq1: PNT1-737 WARN %sPump 1 OUT low pressure warning .......................................................................................................................................................................................................................................................................... 338
34H 125H
8.4.6 Eq1: PNT1-738 PAUS %sPump 1 OUT low pressure fault .................................................................................................................................................................................................................................................................................. 339
345H 126H
8.4.7 Eq1: PNT1-739 WARN %sPump 1 OUT high pressure warning ......................................................................................................................................................................................................................................................................... 339
346H 127H
8.4.8 Eq1: PNT1-740 PAUS %sPump 1 OUT high pressure fault ................................................................................................................................................................................................................................................................................. 339
347H 128H
8.4.9 Eq1: PNT1-744 WARN %sPump 1 motor velocity limit ...................................................................................................................................................................................................................................................................................... 340
348H 129H
8.4.10 Eq1: PNT1-745 WARN %sPump 1 motor servo not ready................................................................................................................................................................................................................................................................................. 340
349H 120H
8.4.11 Eq1: PNT1-746 WARN %sPump 1 totals differ > tolerance .............................................................................................................................................................................................................................................................................. 340
350H 12H
8.4.12 Eq1: PNT1-753 WARN %sPump 2 IN low pressure warning ............................................................................................................................................................................................................................................................................ 340
351H 12H
8.4.13 Eq1: PNT1-754 PAUS %sPump 2 IN low pressure fault .................................................................................................................................................................................................................................................................................... 341
352H 123H
8.4.14 Eq1: PNT1-755 WARN %sPump 2 IN high pressure warning ........................................................................................................................................................................................................................................................................... 341
35H 124H
8.4.15 Eq1: PNT1-756 PAUS %sPump 2 IN high pressure fault ................................................................................................................................................................................................................................................................................... 341
354H 125H
8.4.16 Eq1: PNT1-757 WARN %sPump 2 OUT low pressure warning ........................................................................................................................................................................................................................................................................ 341
35H 126H
8.4.17 Eq1: PNT1-758 PAUS %sPump 2 OUT low pressure fault ................................................................................................................................................................................................................................................................................ 342
356H 127H
8.4.18 Eq1: PNT1-759 WARN %sPump 2 OUT high pressure warning ....................................................................................................................................................................................................................................................................... 342
357H 128H
8.4.19 Eq1: PNT1-760 PAUS %sPump 2 OUT high pressure fault ............................................................................................................................................................................................................................................................................... 343
358H 129H
8.4.20 Eq1: PNT1-761 WARN %sPump 2 fluid flow rate > set point ........................................................................................................................................................................................................................................................................... 343
359H 1230H
8.4.21 Eq1: PNT1-762 WARN %sPump 2 fluid flow rate < set point ........................................................................................................................................................................................................................................................................... 343
360H 123H
8.4.22 Eq1: PNT1-763 WARN %sPump 2 zero fluid flow rate detected ....................................................................................................................................................................................................................................................................... 343
361H 123H
8.4.23 Eq1: PNT1-764 WARN %sPump 2 motor velocity limit .................................................................................................................................................................................................................................................................................... 343
362H 123H
-8-
36H 1234H
364H 1235H
8.4.26 Eq1: PNT1-771 WARN %s Res:Hrd ratio is 0.0:0.0........................................................................................................................................................................................................................................................................................... 344

365H 1236H
36H 1237H
367H 1238H
368H 1239H
369H 1240H
370H 124H
371H 124H
372H 1243H
37H 124H
374H 1245H
375H 1246H
376H 1247H
37H 1248H
378H 1249H
379H 1250H
380H 125H
381H 125H
382H 1253H
38H 1254H
384H 125H
8.4.46 Eq2: PNT1-806 WARN %sPump 2 fluid flow rate > set point ........................................................................................................................................................................................................................................................................... 350
385H 1256H
8.4.47 Eq2: PNT1-807 WARN %sPump 2 fluid flow rate < set point ........................................................................................................................................................................................................................................................................... 350
386H 1257H
8.4.48 Eq2: PNT1-808 WARN %sPump 2 zero fluid flow rate detected ....................................................................................................................................................................................................................................................................... 351
387H 1258H
38H 1259H
389H 1260H
390H 126H
8.4.52 Eq2: PNT1-816 WARN %s Res:Hrd ratio is 0.0:0.0........................................................................................................................................................................................................................................................................................... 351

391H 126H
8.5 Spare Parts and Tools .............................................................................................................................................................................................................................................................................................................................................. 351

392H 1263H
9 Canister Paint Delivery System .............................................................................................................................................................................................................................................................................................. 353

39H 1264H
9.1 Overview ................................................................................................................................................................................................................................................................................................................................................................. 353

394H 1265H
9.1.1 Introduction............................................................................................................................................................................................................................................................................................................................................................ 353

395H 126H

396H 1267H

397H 1268H
9.2.1 Canister Drive Assembly ....................................................................................................................................................................................................................................................................................................................................... 367

398H 1269H
9.2.2 Canister Assembly ................................................................................................................................................................................................................................................................................................................................................. 378

39H 1270H
9.2.3 Canister Manifold Assembly ................................................................................................................................................................................................................................................................................................................................. 380

40H 127H
9.2.4 Paint Supply Components...................................................................................................................................................................................................................................................................................................................................... 385

401H 127H
9.2.5 Dump Line Components ........................................................................................................................................................................................................................................................................................................................................ 409

402H 1273H
9.2.6 Waterborne System Parameters ............................................................................................................................................................................................................................................................................................................................. 440

403H 1274H
9.2.6.1 UIsolation Volume ............................................................................................................................................................................................................................................................................................................................................ 440

40H 1275H

405H 1276H
9.3.1 Preventive Maintenance Schedules........................................................................................................................................................................................................................................................................................................................ 443

406H 127H

407H 1278H
9.4.1 PNT1-894 WARN / PNT1-906 WARN “Low can Pressure after Fill: %s “......................................................................................................................................................................................................................................................... 456
408H 1279H
-9-
9.4.2 PNT1-897 PAUS %s / PNT1-909 PAUS %s “HIGH Negative Canister TORQUE” ........................................................................................................................................................................................................................................... 456
409H 1280H
9.4.3 PNT1-898 PAUS %s / PNT1-910 PAUS %s “HIGH Positive Canister TORQUE”............................................................................................................................................................................................................................................. 457
410H 128H
9.4.4 PNT1-899 PAUS %s / PNT1-911 PAUS %s “Air in Canister detected” .............................................................................................................................................................................................................................................................. 457
41H 128H
9.4.5 PNT1-900 WARN %s / PNT1-912 WARN %s “Low Trigger Torque” ............................................................................................................................................................................................................................................................... 457
412H 1283H
9.4.6 High Voltage Troubleshooting for the Canister Paint Delivery System ................................................................................................................................................................................................................................................................ 457
413H 1284H
9.5 41HSpare Parts & Tools ................................................................................................................................................................................................................................................................................................................................................. 459 1285H

415H 1286H
9.5.2 Tools Required....................................................................................................................................................................................................................................................................................................................................................... 462

416H 1287H
10
417H Color Changer – Canister .................................................................................................................................................................................................................................................................................................... 469 128H
10.1 418H Overview.............................................................................................................................................................................................................................................................................................................................................................. 4691289H
10.2 419H Operations and Setup ........................................................................................................................................................................................................................................................................................................................................... 471 1290H
10.2.1 Five Valve SolvAir Module................................................................................................................................................................................................................................................................................................................................. 471

420H 129H
10.2.2 Color Module – Recirculating.............................................................................................................................................................................................................................................................................................................................. 473

421H 129H
10.2.3 Non-Recirculating Color Module ........................................................................................................................................................................................................................................................................................................................ 475

42H 1293H
10.2.4 End Block............................................................................................................................................................................................................................................................................................................................................................. 477

423H 1294H
10.2.5 Maintenance and Repair....................................................................................................................................................................................................................................................................................................................................... 478

42H 1295H
10.2.6 Paint Valve Maintenance ..................................................................................................................................................................................................................................................................................................................................... 490

425H 1296H
10.2.7 SolvAir Module ................................................................................................................................................................................................................................................................................................................................................... 490

426H 1297H
10.2.8 Color Module ....................................................................................................................................................................................................................................................................................................................................................... 490

427H 1298H
10.3 428H Troubleshooting ................................................................................................................................................................................................................................................................................................................................................... 491 129H
10.3.1 SolvAir Module ................................................................................................................................................................................................................................................................................................................................................... 491

429H 130H
10.3.2 Color Module ....................................................................................................................................................................................................................................................................................................................................................... 491

430H 130H
10.4 431H Spare Parts and Tools........................................................................................................................................................................................................................................................................................................................................... 492 1302H
11
432H Color Changer – IPC............................................................................................................................................................................................................................................................................................................. 501 130H
11.1 43H Overview.............................................................................................................................................................................................................................................................................................................................................................. 5011304H
11.2 43H Operations and Setup ........................................................................................................................................................................................................................................................................................................................................... 507 1305H
11.2.1 SolvAir Module ................................................................................................................................................................................................................................................................................................................................................... 507

435H 1306H
11.2.2 Color Module – Recirculating.............................................................................................................................................................................................................................................................................................................................. 510

436H 1307H
11.2.3 Non-Recirculating Color Module ........................................................................................................................................................................................................................................................................................................................ 512

437H 1308H
11.2.4 Pressure Regulator ............................................................................................................................................................................................................................................................................................................................................... 513

438H 1309H
11.2.5 Pressure Regulator (Fixed)................................................................................................................................................................................................................................................................................................................................... 513

439H 130H
11.2.6 Maintenance and Repair....................................................................................................................................................................................................................................................................................................................................... 515

40H 13H
11.2.7 SolvAir Module ................................................................................................................................................................................................................................................................................................................................................... 520

41H 132H
11.2.8 Color Module ....................................................................................................................................................................................................................................................................................................................................................... 520

42H 13H
11.3 43H Troubleshooting ................................................................................................................................................................................................................................................................................................................................................... 521 134H
11.3.1 SolvAir Module ................................................................................................................................................................................................................................................................................................................................................... 521

4H 135H
11.3.2 Color Module ....................................................................................................................................................................................................................................................................................................................................................... 521

45H 136H
11.4 46H Spare parts and special tools ................................................................................................................................................................................................................................................................................................................................ 522 137H
-10-
TABLE OF FIGURES MARMCP7AP07071E REV. C
TABLE OF FIGURES
Figure 2-1: ITW HV mounting dimensions ...................................................................................................................................................................................................................................................................................................................... 24
47H 138H
Figure 2-2: High Voltage Controller Layout .................................................................................................................................................................................................................................................................................................................... 25

48H 139H
Figure 2-3: ITW HV controller connections..................................................................................................................................................................................................................................................................................................................... 27

49H 1320H
Figure 2-4: ITW legacy cascade (EE-4526-800) .............................................................................................................................................................................................................................................................................................................. 28

450H 132H
Figure 2-5: ITW integrated cascade (EE4526-801) .......................................................................................................................................................................................................................................................................................................... 28

451H 132H
Figure 2-6: High voltage cable.......................................................................................................................................................................................................................................................................................................................................... 29

452H 132H
Figure 2-7: ITW Start-Up Menu ....................................................................................................................................................................................................................................................................................................................................... 31

453H 1324H
Figure 2-8: ITW Run Menu .............................................................................................................................................................................................................................................................................................................................................. 31

45H 1325H
Figure 2-9: ITW Mode Menu............................................................................................................................................................................................................................................................................................................................................ 31

45H 1326H
Figure 2-10: ITW Sensitivity Menu.................................................................................................................................................................................................................................................................................................................................. 32

456H 1327H
Figure 2-11: ITW Fault Menu........................................................................................................................................................................................................................................................................................................................................... 32

457H 1328H
Figure 2-12: ITW IP Address Menu ................................................................................................................................................................................................................................................................................................................................. 32

458H 1329H
Figure 2-13: High voltage system components................................................................................................................................................................................................................................................................................................................. 46

459H 130H
Figure 2-14: High voltage start up screen ......................................................................................................................................................................................................................................................................................................................... 47

460H 13H
Figure 2-15: High voltage main menu .............................................................................................................................................................................................................................................................................................................................. 47

461H 132H
Figure 2-16: High voltage controller LED indicators ....................................................................................................................................................................................................................................................................................................... 48

462H 13H
Figure 2-17: High voltage backplane............................................................................................................................................................................................................................................................................................................................... 49

463H 134H
Figure 2-18: High voltage legacy cascade (EO-4526-110-000) ....................................................................................................................................................................................................................................................................................... 54

46H 135H
Figure 2-19: High voltage integrated cascade (EE-4696-800) ......................................................................................................................................................................................................................................................................................... 54

465H 136H
Figure 2-20: High voltage cable........................................................................................................................................................................................................................................................................................................................................ 54

46H 137H
Figure 2-21: High voltage Step X ..................................................................................................................................................................................................................................................................................................................................... 68

467H 138H
Figure 2-22: High voltage set voltage............................................................................................................................................................................................................................................................................................................................... 68

468H 139H
Figure 2-23: High voltage set current ............................................................................................................................................................................................................................................................................................................................... 68

469H 1340H
Figure 2-24: High voltage local mode key switch ............................................................................................................................................................................................................................................................................................................ 69

470H 134H
Figure 2-25: High voltage high voltage controller unit in Step X mode........................................................................................................................................................................................................................................................................... 69
471H 1342H
Figure 2-26: High voltage HV disable button................................................................................................................................................................................................................................................................................................................... 69

472H 134H
Figure 2-27: P-500 HV cable ............................................................................................................................................................................................................................................................................................................................................ 71

473H 134H
Figure 2-28: P-500 applicator quick disconnect .............................................................................................................................................................................................................................................................................................................. 72

47H 1345H
Figure 2-29: P-500 process bundle clamp......................................................................................................................................................................................................................................................................................................................... 72

475H 1346H
Figure 2-30: P-500 HV cable / cascade connection .......................................................................................................................................................................................................................................................................................................... 73

476H 1347H
Figure 2-31: HV cable part number label ......................................................................................................................................................................................................................................................................................................................... 73

47H 1348H
Figure 2-32: HV Cable in applicator QD

478H Figure 2-33: HV Cable pulled through applicator QD............................................................................................................................................................................................................................. 74 1349H
Figure 2-34: HV cable inside of robot wrist ..................................................................................................................................................................................................................................................................................................................... 74

479H 1350H
Figure 2-35: HV cable fed back through process bundle clamp ....................................................................................................................................................................................................................................................................................... 75
480H 135H
Figure 2-36: HV cable / cascade connection..................................................................................................................................................................................................................................................................................................................... 75

481H 1352H
Figure 2-37: Process bundle clamp bolt position.............................................................................................................................................................................................................................................................................................................. 76

482H 135H
Figure 2-38: HV cable part number position .................................................................................................................................................................................................................................................................................................................... 76

483H 1354H
Figure 2-39: Dielectric grease locations .......................................................................................................................................................................................................................................................................................................................... 77

48H 135H
Figure 2-40: Clean grease locations................................................................................................................................................................................................................................................................................................................................. 78

485H 1356H
Figure 2-41: High voltage petticoat location .................................................................................................................................................................................................................................................................................................................... 78

486H 1357H
Figure 2-42: Dielectric grease applied to a cascade.......................................................................................................................................................................................................................................................................................................... 79

487H 1358H
Figure 2-43: Fanuc Robotics dielectric grease................................................................................................................................................................................................................................................................................................................. 79

48H 1359H
-11-
MARMCP7AP07071E REV. C 1 VERSABELL II+ APPLICATOR
Figure 2-44: Cascade dielectric locations ........................................................................................................................................................................................................................................................................................................................ 80

489H 1360H
Figure 2-45: Cascade loaction for NO dielectric grease ................................................................................................................................................................................................................................................................................................... 80

490H 136H
Figure 3-1: D/Q PCE Block Diagram ............................................................................................................................................................................................................................................................................................................................... 88

491H 1362H
Figure 3-2: Flowmeter Block Diagram Overview ............................................................................................................................................................................................................................................................................................................ 89

492H 136H
Figure 3-3: P-500iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview...................................................................................................................................................................................................................... 90
493H 1364H
Figure 3-4: P-500iA Process Control Enclosure with Air Flowmeter – Bell Speed Control Components....................................................................................................................................................................................................................... 91
49H 1365H
Figure 3-5: P-500iA D/Q Process Control Enclosure – Bell Speed Control Components ............................................................................................................................................................................................................................................... 92
495H 136H
Figure 3-6: P-700iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview...................................................................................................................................................................................................................... 93
496H 1367H
Figure 3-7: P-700iA Process Control Enclosure with Air Flowmeter – Bell Speed Control Components....................................................................................................................................................................................................................... 94
497H 1368H
Figure 3-8: P-700iA D/Q Process Control Enclosure – Bell Speed Control Components ............................................................................................................................................................................................................................................... 96
498H 1369H
Figure 3-9: Festo MPPE (TDUCO000000004O) - Turbine Drive I/P.............................................................................................................................................................................................................................................................................. 96

49H 1370H
Figure 3-10: SMC ITV 2050 (TDUCO000000019O) - Turbine Drive I/P .................................................................................................................................................................................................................................................................... 97
50H 137H
Figure 3-11: O/E Installation ............................................................................................................................................................................................................................................................................................................................................ 98

501H 1372H
Figure 3-12: Optical Fiber Insertion ................................................................................................................................................................................................................................................................................................................................. 98

502H 137H
Figure 3-13: O/E Level Setting......................................................................................................................................................................................................................................................................................................................................... 99

503H 1374H
Figure 3-14: O/E Mode selection...................................................................................................................................................................................................................................................................................................................................... 99

504H 1375H
Figure 3-15: O/E key lock display .................................................................................................................................................................................................................................................................................................................................. 100

50H 1376H
Figure 3-16: F/I – side view............................................................................................................................................................................................................................................................................................................................................ 100

506H 137H
Figure 3-17: F/I Terminal Connections ...................................................................................................................................................................................................................................................................................................................... 101

507H 1378H
Figure 3-18: F/I Faceplate............................................................................................................................................................................................................................................................................................................................................... 101

508H 1379H
Figure 3-19: Turbine Dowels and Mirror Window........................................................................................................................................................................................................................................................................................................ 102

509H 1380H
Figure 3-20: Elbow Manifold dowel holes and fiber-optic line..................................................................................................................................................................................................................................................................................... 102
510H 138H
Figure 3-21: Fiber Optic connection points .................................................................................................................................................................................................................................................................................................................... 103

51H 1382H
Figure 3-22: STARTUP Bell Speed screen .................................................................................................................................................................................................................................................................................................................... 104

512H 138H
Figure 3-23: Turbine speed wheel mirror location ........................................................................................................................................................................................................................................................................................................ 114

513H 1384H
Figure 3-24: Elbow Manifold fiber-optic cable .............................................................................................................................................................................................................................................................................................................. 115

514H 1385H
Figure 3-25: Applicator fiber-optic cable nose location ................................................................................................................................................................................................................................................................................................. 116

51H 1386H
Figure 3-26: Applicator fiber-optic rear location............................................................................................................................................................................................................................................................................................................ 117

516H 1387H
Figure 3-27: Wrist Fiber-Optic Cable location .............................................................................................................................................................................................................................................................................................................. 118

517H 138H
Figure 4-1: Bearing Air Schematic ................................................................................................................................................................................................................................................................................................................................. 123

518H 1389H
Figure 4-2: Manual supply pressure regulator on the Pneumatic Supply Panel ............................................................................................................................................................................................................................................................. 124
519H 1390H
Figure 4-3: Accumulator tank location on the Pneumatic Supply Panel ........................................................................................................................................................................................................................................................................ 124
520H 139H
Figure 5-1: D/Q Shape Air Schematic ............................................................................................................................................................................................................................................................................................................................ 127

521H 1392H
Figure 5-2: Communication connection point ............................................................................................................................................................................................................................................................................................................... 128

52H 139H
Figure 5-3: D/Q valve block (EO-4696-110-008 & EO-4696-110-011) ........................................................................................................................................................................................................................................................................ 129
523H 1394H
Figure 5-4: Pressure Sensor (P/I) (SENSO000000451O)............................................................................................................................................................................................................................................................................................... 130

524H 1395H
Figure 5-5: D/Q Valve Calibration Screen in PaintWorks.............................................................................................................................................................................................................................................................................................. 131

52H 1396H
Figure 5-6: Shape Air Sense Calibration Screen in PaintWorks..................................................................................................................................................................................................................................................................................... 132

526H 1397H
Figure 5-7: Fluid Maintenance Screen in PaintWorks.................................................................................................................................................................................................................................................................................................... 133

527H 1398H
Figure 5-8: Calibration Screw Covers ............................................................................................................................................................................................................................................................................................................................ 135

528H 139H
Figure 5-9: Upper & lower valve block orientation........................................................................................................................................................................................................................................................................................................ 136

529H 140H
Figure 5-10: Evaluation of piston in cylinder ................................................................................................................................................................................................................................................................................................................. 136

530H 140H
Figure 5-11: Pipe Plug & Seal Removal ......................................................................................................................................................................................................................................................................................................................... 137

531H 1402H
Figure 5-12: Orifice Removal ......................................................................................................................................................................................................................................................................................................................................... 137

532H 1403H
Figure 5-13: Orifice Cleaning ......................................................................................................................................................................................................................................................................................................................................... 138

53H 140H
Figure 5-14: Orientation of Internal Parts for Assembly ................................................................................................................................................................................................................................................................................................ 138

534H 1405H
-12-
Figure 5-15: O-Rings Removal....................................................................................................................................................................................................................................................................................................................................... 139

53H 1406H
Figure 5-16: Location of O-Rings................................................................................................................................................................................................................................................................................................................................... 140

536H 1407H
Figure 5-17: Upper & Lower Valve Block Orientation .................................................................................................................................................................................................................................................................................................. 140
537H 1408H
Figure 5-18: Upper Valve Block O-Rings ...................................................................................................................................................................................................................................................................................................................... 141

538H 1409H
Figure 5-19: O-Ring Removal ........................................................................................................................................................................................................................................................................................................................................ 141

539H 140H
Figure 5-20: O-Ring Installation..................................................................................................................................................................................................................................................................................................................................... 141

540H 14H
Figure 5-21: Removal of Pipe Plug with Seal................................................................................................................................................................................................................................................................................................................. 143

541H 142H
Figure 5-22: Orifice Removal ......................................................................................................................................................................................................................................................................................................................................... 143

542H 143H
Figure 5-23: D/Q cap Removal....................................................................................................................................................................................................................................................................................................................................... 144

543H 14H
Figure 5-24: D/Q Manifold Removal.............................................................................................................................................................................................................................................................................................................................. 144

54H 145H
Figure 5-25: D/Q Cup Seals............................................................................................................................................................................................................................................................................................................................................ 144

54H 146H
Figure 5-26: D/Q Manifold Alignment ........................................................................................................................................................................................................................................................................................................................... 145

546H 147H
Figure 6-1: Single Shape Air AccuAir Schematic ......................................................................................................................................................................................................................................................................................................... 155

547H 148H
Figure 6-2: Dual Shape Air AccuAir Schematic............................................................................................................................................................................................................................................................................................................ 156

548H 149H
Figure 6-3: Flow meter components. P-700iA PCE ...................................................................................................................................................................................................................................................................................................... 157

549H 1420H
Figure 6-4: Flow meter components. P-500iA PCE ...................................................................................................................................................................................................................................................................................................... 158

50H 142H
Figure 6-5: Pressure Transducer, P-700iA PCE ............................................................................................................................................................................................................................................................................................................. 159

51H 142H
Figure 6-6: Pressure Transducer, P-500iA PCE ............................................................................................................................................................................................................................................................................................................. 159

52H 1423H
Figure 7-1: P-500iA Manual seal air regulator ............................................................................................................................................................................................................................................................................................................... 165

53H 142H
Figure 7-2: P-700 Seal air manual regulator ................................................................................................................................................................................................................................................................................................................... 165

54H 1425H
Figure 7-3: Gap between seal air nozzle and shape air nozzle........................................................................................................................................................................................................................................................................................ 166
5H 1426H
Figure 8-1 ET-5093-890-007 Sheet 1 of 2, 1K PUMP ................................................................................................................................................................................................................................................................................................. 170

56H 1427H
Figure 8-2 ET-5093-890-007 Sheet 2 of 2, 1K PUMP ................................................................................................................................................................................................................................................................................................. 171

57H 1428H
Figure 8-3 ET-6102-890-007 Sheet 1 of 2, ZENITH PUMP MAINTENANCE ......................................................................................................................................................................................................................................................... 172

58H 1429H
Figure 8-4 ET-6102-890-007 Sheet 2 of 2, ZENITH PUMP MAINTENANCE ......................................................................................................................................................................................................................................................... 173

59H 1430H
Figure 8-5 EG-00384 Sheet 1 of 4, P-700 2K 1+1 SCHEMATIC - VAR. REG.......................................................................................................................................................................................................................................................... 174
560H 143H
561H 1432H
562H 143H
563H 143H
Figure 8-9 EG-00385 Sheet 1 of 3, P-700 1K WITH FIX REG SCHEMATICS......................................................................................................................................................................................................................................................... 178
564H 1435H
Figure 8-10 EG-00385 Sheet 2 of 3, P-700 1K WITH FIX REG SCHEMATICS....................................................................................................................................................................................................................................................... 179
56H 1436H
Figure 8-11 EG-00385 Sheet 3 of 3, P-700 1K WITH FIX REG SCHEMATICS....................................................................................................................................................................................................................................................... 180
56H 1437H
Figure 8-12 EG-00387 Sheet 1 of 4, P-700 2K 1+1 SCHEMATIC - FIXED REG. .................................................................................................................................................................................................................................................... 181
567H 1438H
568H 1439H
569H 140H
570H 14H
Figure 8-16 EG-00388 Sheet 1 of 4, MULTIRESIN 2K SCHEMATIC - VAR. REG. ............................................................................................................................................................................................................................................... 185
571H 142H
572H 143H
573H 14H
574H 145H
Figure 8-20 EG-00389 Sheet 1 of 4, MULTIRESIN 2K SCHEMATIC - FIX REG ................................................................................................................................................................................................................................................... 189
57H 146H
576H 147H
57H 148H
578H 149H
Figure 8-24 EG-00401 Sheet 1 of 3, 1K FESTO WITH REG SCHEMATICS ........................................................................................................................................................................................................................................................... 193
579H 1450H
Figure 8-25 EG-00401 Sheet 2 of 3, 1K FESTO WITH REG SCHEMATICS ........................................................................................................................................................................................................................................................... 194
580H 145H
-13-
Figure 8-26
581H EG-00401 Sheet 3 of 3, 1K FESTO WITH REG SCHEMATICS ........................................................................................................................................................................................................................................................... 195
1452H
Figure 8-27
582H EG-00402 Sheet 1 of 3, P-500iA 1K W/ FIXED REG SCHEM .............................................................................................................................................................................................................................................................. 196
1453H
Figure 8-28
145H
Figure 8-29
145H
Figure 8-30
58H EG-00410 Sheet 1 of 3, P-700 GUN OPTION 1K WITH FIX REG SCHEMATICS ............................................................................................................................................................................................................................. 199 1456H
Figure 8-31
Figure 8-32
Figure 8-33
58H EG-00411 Sheet 1 of 3, P-700 GUN OPTION 1K WITH REG SCHEMATICS..................................................................................................................................................................................................................................... 202 1459H
Figure 8-34
Figure 8-35
Figure 8-36
591H EG-00412 Sheet 1 of 3, P-700 GUN OPTION WB SCHEMATICS........................................................................................................................................................................................................................................................ 2051462H
Figure 8-37
Figure 8-38
Figure 8-39
594H EG-00413 Sheet 1 of 4, P-700 GUN OPTION 2K 1+1 SCHEMATICS - FIXED REG. ......................................................................................................................................................................................................................... 208 1465H
Figure 8-40
Figure 8-41
Figure 8-42
Figure 8-43
598H EG-00414 Sheet 1 of 4, P-700 GUN OPTION 2K 1+1 SCHEMATIC - VAR. REG. ............................................................................................................................................................................................................................. 212 1469H
Figure 8-44
Figure 8-45
Figure 8-46
Figure 8-47
602H EG-00415 Sheet 1 of 4, GUN OPTION MULTIRESIN 2K SCHEMATIC - FIXED REG..................................................................................................................................................................................................................... 216 1473H
Figure 8-48
Figure 8-49
Figure 8-50
Figure 8-51
60H EG-00416 Sheet 1 of 4, GUN OPTION MULTIRESIN 2K SCHEMATIC - VAR. REG. ...................................................................................................................................................................................................................... 220 147H
Figure 8-52
Figure 8-53
Figure 8-54
Figure 8-55
610H EG-00440 Sheet 1 of 3, P-700 SMC 1K WITH REG SCHEMATICS..................................................................................................................................................................................................................................................... 224 148H
Figure 8-56
Figure 8-57
Figure 8-58
613H EG-00441 Sheet 1 of 3, P-700 SMC 1K FIXED REG SCHEMATICS ................................................................................................................................................................................................................................................... 227 148H
Figure 8-59
Figure 8-60
Figure 8-61
61H EG-00442 Sheet 1 of 4, 1K SMC WITH REG SCHEMATICS ............................................................................................................................................................................................................................................................... 230
1487H
Figure 8-62
148H
Figure 8-63
1489H
Figure 8-64
1490H
Figure 8-65
620H EG-00443 Sheet 1 of 3, P-500iA 1K WITH REG SCHEMATICS .......................................................................................................................................................................................................................................................... 234
149H
Figure 8-66
1492H
Figure 8-67
1493H
Figure 8-68
623H EG-00444 Sheet 1 of 4, 1K SMC FIXED REG SCHEMATICS.............................................................................................................................................................................................................................................................. 237
149H
Figure 8-69
1495H
Figure 8-70
1496H
Figure 8-71
1497H
-14-
Figure 8-72 EG-00448 Sheet 1 of 3, P-700 SMC DUAL SHAPE AIR 1K WITH REG SCHEMATICS ................................................................................................................................................................................................................... 241
627H 1498H
628H 149H
629H 150H
Figure 8-75 EG-00449 Sheet 1 of 3, P-700 SMC DUAL SHAPE AIR 1K FIX REG SCHEMATICS ....................................................................................................................................................................................................................... 244
630H 150H
631H 1502H
632H 1503H
Figure 8-78 EG-00457 Sheet 1 of 4, P-700 SMC 2K 1+1 FIX REG SCHEMATIC.................................................................................................................................................................................................................................................... 247
63H 1504H
634H 150H
635H 1506H
63H 1507H
Figure 8-82 EG-00458 Sheet 1 of 4, P-700 SMC 2K 1+1 WITH REG SCHEMATIC................................................................................................................................................................................................................................................ 251
637H 1508H
638H 1509H
639H 150H
640H 15H
Figure 8-86 EG-00485 Sheet 1 of 4, P700 SMC 2K 24+3 SCHEMATIC FIXED REG.............................................................................................................................................................................................................................................. 255
641H 152H
642H 153H
643H 154H
64H 15H
Figure 8-90 EG-00486 Sheet 1 of 4, P700 SMC 2K 24+3 VAR REG SCHEMATIC ................................................................................................................................................................................................................................................. 259
645H 156H
64H 157H
647H 158H
648H 159H
Figure 8-94 EG-00494 Sheet 1 of 4, P-500iA SMC 2K 24+3 VAR REG SCHEMAT................................................................................................................................................................................................................................................ 263
649H 1520H
650H 152H
651H 152H
652H 1523H
Figure 8-98 EG-00495 Sheet 1 of 4, P-500iA SMC 2K 24+3 FIXED REG SCHEM.................................................................................................................................................................................................................................................. 267
653H 1524H
Figure 8-99 EG-00495 Sheet 2 of 4, P-500iA SMC 2K 24+3 FIXED REG SCHEM.................................................................................................................................................................................................................................................. 268
654H 152H
Figure 8-100 EG-00495 Sheet 3 of 4, P-500iA SMC 2K 24+3 FIXED REG SCHEM................................................................................................................................................................................................................................................ 269
65H 1526H
Figure 8-101 EG-00495 Sheet 4 of 4, P-500iA SMC 2K 24+3 FIXED REG SCHEM................................................................................................................................................................................................................................................ 270
65H 1527H
Figure 8-102 EG-00499 Sheet 1 of 4, P700 SMC DUAL SA 2K 24+3 SCHEMATIC FIXED REG ......................................................................................................................................................................................................................... 271
657H 1528H
658H 1529H
659H 1530H
60H 153H
Figure 8-106 EG-00500 Sheet 1 of 4, P700 SMC DUAL SA 2K 24+3 VAR REG SCHEMATIC............................................................................................................................................................................................................................. 275
61H 1532H
62H 153H
63H 1534H
64H 153H
Figure 8-110 EG-00513 Sheet 1 of 3, P-250iB 1K WITH REG SCHEMATICS ........................................................................................................................................................................................................................................................ 279
65H 1536H
6H 1537H
67H 1538H
Figure 8-113 EG-00514 Sheet 1 of 3, P-250iB SINGLE SA 1K FIX REG SCHEMATICS ....................................................................................................................................................................................................................................... 282
68H 1539H
69H 1540H
670H 154H
Figure 8-116 EG-00515 Sheet 1 of 3, P-250iB 1K DUAL SA WITH REG SCHEMATICS ...................................................................................................................................................................................................................................... 285
671H 1542H
Figure 8-117 EG-00515 Sheet 2 of 3, P-250iB 1K DUAL SA WITH REG SCHEMATICS ...................................................................................................................................................................................................................................... 286
672H 1543H
-15-
Figure 8-118
673H EG-00515 Sheet 3 of 3, P-250iB 1K DUAL SA WITH REG SCHEMATICS ...................................................................................................................................................................................................................................... 287 154H
Figure 8-119
674H EG-00516 Sheet 1 of 3, P-250iB 1K DUAL SA FIXED REG SCHEMATICS..................................................................................................................................................................................................................................... 288 154H
Figure 8-120
Figure 8-121
Figure 8-122
67H EO-5093-521-000, PUMP MANIFOLD ASSEMBLY .......................................................................................................................................................................................................................................................................... 291 1548H
Figure 8-123
678H EO-6102-521-000, 1K PUMP BLOCK ASM......................................................................................................................................................................................................................................................................................... 292 1549H
Figure 8-124
679H EO-5093-526-000, 1K Pump W/ Vent QD ASSY.................................................................................................................................................................................................................................................................................. 293 150H
Figure 8-125
680H EO-4696-526-000, 3CC Pump ................................................................................................................................................................................................................................................................................................................ 294
15H
Figure 8-126
681H EO-4657-511-000 Sheet 1, 3CC GEAR PUMP...................................................................................................................................................................................................................................................................................... 295 152H
Figure 8-127
682H EO-4657-512-000 Sheet 1 of 2, 6CC GEAR PUMP .............................................................................................................................................................................................................................................................................. 296 153H
Figure 8-128
683H EG-00422 Sheet 1 of 8, Standard Flow Rate Measurement Procedure - Paint ....................................................................................................................................................................................................................................... 299 154H
Figure 8-129
Figure 8-130
Figure 8-131
Figure 8-132
Figure 8-133
Figure 8-134
Figure 8-135
Figure 8-136
691H EO-5093-516-000 Sheet 1 of 4, 2K 1+1 MANIFOLD ASSEMBLY ..................................................................................................................................................................................................................................................... 307 1562H
Figure 8-137
Figure 8-138
Figure 8-139
Figure 8-140
695H ET-5093-895-002 Sheet 1 of 3, P-700iA 2K 24+3 MANIFOLD MAINTENANCE ............................................................................................................................................................................................................................. 311 156H
Figure 8-141
Figure 8-142
Figure 8-143
698H ET-5093-895-003, P-700iA 2K FLOW METER MAINTENANCE...................................................................................................................................................................................................................................................... 314 1569H
Figure 8-144
69H ET-6102-890-006 Sheet 1 of 2, P-500iA 1K PM SCHEDULES............................................................................................................................................................................................................................................................ 316 1570H
Figure 8-145
70H ET-6102-890-006 Sheet 2 of 2, P-500iA 1K PM SCHEDULES............................................................................................................................................................................................................................................................ 317 157H
Figure 8-146
701H ET-6102-890-007 Sheet 1 of 2, ZENITH PUMP MAINTENANCE ..................................................................................................................................................................................................................................................... 318 1572H
Figure 8-147
702H ET-6102-890-007 Sheet 2 of 2, ZENITH PUMP MAINTENANCE ..................................................................................................................................................................................................................................................... 319 1573H
Figure 8-148
703H ET-5093-890-006 Sheet 1 of 2, P700 1K PM SCHEDULES ................................................................................................................................................................................................................................................................. 320 1574H
Figure 8-149
704H ET-5093-890-006 Sheet 2 of 2, P700 1K PM SCHEDULES ................................................................................................................................................................................................................................................................. 321 157H
Figure 8-150
705H EG-00421 Sheet 1 of 7, Serto PA/PVDF Fitting Installation Instructions.............................................................................................................................................................................................................................................. 322 1576H
Figure 8-151
Figure 8-152
Figure 8-153
Figure 8-154
Figure 8-155
Figure 8-156
Figure 8-157
712H EG-00573 Sheet 1 of 5, Parker Parklok Installation Instructions ........................................................................................................................................................................................................................................................... 329 1583H
Figure 8-158
713H EG-00573 Sheet 2 of 5 Parker Parklok Installation Instructions ............................................................................................................................................................................................................................................................ 330 1584H
Figure 8-159
Figure 8-160
Figure 8-161
Figure 8-162
71H EG-00492, Check Valve Installation Instructions................................................................................................................................................................................................................................................................................... 334 158H
Figure 8-163
718H EG-00566 Sheet 1 of 2, Released............................................................................................................................................................................................................................................................................................................ 335
1589H
-16-
Figure 8-164 EG-00566 Sheet 2 of 2, Released............................................................................................................................................................................................................................................................................................................ 336

719H 1590H
Figure 9-1 EG-00390 Sheet 1 of 3, P-700 WB SCHEMATICS................................................................................................................................................................................................................................................................................... 354

720H 159H

721H 1592H

72H 1593H
Figure 9-4 EG-00403 Sheet 1 of 3, P-500iA WATERBORNE SCHEM ..................................................................................................................................................................................................................................................................... 357

723H 1594H

724H 159H

725H 1596H
Figure 9-7 EG-00446 Sheet 1 of 3, SMC WB/Single Shape Air Schematics............................................................................................................................................................................................................................................................... 360
726H 1597H
72H 1598H
728H 159H
Figure 9-10 EG-00456 Sheet 1 of 3, P-700 SMC WB SCHEMATICS ....................................................................................................................................................................................................................................................................... 363

729H 160H

730H 160H

731H 1602H
Figure 9-13 DOC-5093-CPDS-Schematic, CANISTER SYSTEM SCHEMATIC...................................................................................................................................................................................................................................................... 366

732H 1603H
Figure 9-14 EO-4696-330-000, CANISTER DRIVE ASSEMBLY............................................................................................................................................................................................................................................................................. 367

73H 1604H
Figure 9-15 EO-6102-025-000 Sheet 1 of 2, P-500iA WB OUTER ARM .................................................................................................................................................................................................................................................................. 368

734H 1605H

735H 160H
Figure 9-17 EO-6246-025-000 Sheet 1 of 4, P-700 FLEX WB OUTER ARM ASM.................................................................................................................................................................................................................................................. 370
736H 1607H
73H 1608H
738H 1609H
739H 160H

740H 16H

741H 162H

742H 163H

743H 164H
Figure 9-25 EO-5093-320-000, CANISTER ASSEMBLY.......................................................................................................................................................................................................................................................................................... 379

74H 165H
Figure 9-26 EO-4696-310-000, CANISTER MANIFOLD .......................................................................................................................................................................................................................................................................................... 381

745H 16H
Figure 9-27 EO-5093-310-000, CANISTER MANIFOLD ASM ................................................................................................................................................................................................................................................................................ 382

746H 167H
Figure 9-28 EO-5093-310-002, CANISTER MANIFOLD ASM ................................................................................................................................................................................................................................................................................ 383

74H 168H
Figure 9-29 EO-6263-310-002, 3 WAY MANIFOLD ................................................................................................................................................................................................................................................................................................. 384

748H 169H
Figure 9-30 EO-6102-800-004 Sheet 1 of 5, P-500iA R30iA WB PAINTER ASM ................................................................................................................................................................................................................................................... 386
749H 1620H
750H 162H
751H 162H
752H 1623H
753H 1624H
Figure 9-35 EO-5093-895-002 Sheet 1 of 8, P-700 WB PROCESS HARDWARE ASM........................................................................................................................................................................................................................................... 391

754H 1625H

75H 162H

756H 1627H

75H 1628H

758H 1629H

759H 1630H

760H 163H

761H 1632H
Figure 9-43 EO-6263-895-002 Sheet 1 of 5, WB PROCESS INSTALLATION......................................................................................................................................................................................................................................................... 399

762H 163H

763H 1634H

764H 1635H
-17-
Figure 9-46
765H EO-6263-895-002 Sheet 4 of 5, WB PROCESS INSTALLATION......................................................................................................................................................................................................................................................... 402 163H
Figure 9-47
76H EO-6263-895-002 Sheet 5 of 5, WB PROCESS INSTALLATION......................................................................................................................................................................................................................................................... 403 1637H
Figure 9-48
76H EO-5093-262-007, ISOLATION LINE .................................................................................................................................................................................................................................................................................................... 404
1638H
Figure 9-49
768H EO-5093-310-011, ISOLATION MANIFOLD ASSEMBLY .................................................................................................................................................................................................................................................................. 405 1639H
Figure 9-50
769H EO-5093-310-013, ISOLATION MANIFOLD ASSEMBLY .................................................................................................................................................................................................................................................................. 406 1640H
Figure 9-51
70H EO-6102-270-000 Sheet 1 of 2, STICK DUMP ASM.............................................................................................................................................................................................................................................................................. 409 164H
Figure 9-52
71H EO-6102-270-000 Sheet 2 of 2, STICK DUMP ASM.............................................................................................................................................................................................................................................................................. 410 1642H
Figure 9-53
72H EO-5093-262-000 Sheet 1 of 12, WB COLOR LINE ASSEMBLY ........................................................................................................................................................................................................................................................ 411 1643H
Figure 9-54
Figure 9-55
Figure 9-56
Figure 9-57
Figure 9-58
Figure 9-59
Figure 9-60
Figure 9-61
Figure 9-62
781H EO-5093-262-000 Sheet 10 of 12, WB COLOR LINE ASSEMBLY ...................................................................................................................................................................................................................................................... 420 1652H
Figure 9-63
Figure 9-64
Figure 9-65
784H EO-5093-515-010, DUMP ISOLATION LINE........................................................................................................................................................................................................................................................................................ 423 165H
Figure 9-66
785H EO-5093-310-014, DUMP "Y" BLOCK .................................................................................................................................................................................................................................................................................................. 424
165H
Figure 9-67
786H EO-5093-310-017, 3 WAY MANIFOLD ................................................................................................................................................................................................................................................................................................. 425
1657H
Figure 9-68
78H EO-6263-310-001, 2-WAY DUMP MANIFOLD ASM........................................................................................................................................................................................................................................................................... 426 1658H
Figure 9-69
78H EO-5093-515-011, DUMP ISOLATION LINE (P-250iB)....................................................................................................................................................................................................................................................................... 427 1659H
Figure 9-70
789H EO-4696-271-000-3, Isocore Line Strip Procedure .................................................................................................................................................................................................................................................................................. 428
160H
Figure 9-71
16H
Figure 9-72
162H
Figure 9-73
163H
Figure 9-74
164H
Figure 9-75
165H
Figure 9-76
16H
Figure 9-77
796H EO-4696-271-000-10, Isocore Line Strip Procedure ................................................................................................................................................................................................................................................................................ 435
167H
Figure 9-78
168H
Figure 9-79
169H
Figure 9-80
1670H
Figure 9-81
80H ET-5093-895-006 Sheet 1 of 4, WB Maintenance Schedules................................................................................................................................................................................................................................................................... 443 167H
Figure 9-82
Figure 9-83
Figure 9-84
Figure 9-85
804H EG-00423 Sheet 1 of 4, Water Heater Temp. Switch Setting Proc........................................................................................................................................................................................................................................................... 447 1675H
Figure 9-86
Figure 9-87
Figure 9-88
Figure 9-89
80H EG-00573 Sheet 1 of 5, Parker Parklok Installation Instructions ............................................................................................................................................................................................................................................................. 451 1679H
Figure 9-90
Figure 9-91
-18-
Figure 9-92 EG-00573 Sheet 4 of 5, Parker Parklok Installation Instructions ............................................................................................................................................................................................................................................................. 454
81H 1682H
Figure 9-93 EG-00573 Sheet 5 of 5, Parker Parklok Installation Instructions ............................................................................................................................................................................................................................................................. 455
812H 1683H
Figure 9-94 EO-5513-003-000, Gen II Paint Valve...................................................................................................................................................................................................................................................................................................... 460

813H 1684H
Figure 9-95 EO-4696-330-022, CONNECTION PIN .................................................................................................................................................................................................................................................................................................. 461

814H 1685H
Figure 9-96 EO-5513-700-003, VALVE TOOL .......................................................................................................................................................................................................................................................................................................... 463

815H 168H
Figure 9-97 EO-4526-700-008, HOSE DEPTH TOOL................................................................................................................................................................................................................................................................................................ 464

816H 1687H
Figure 9-98 EO-4526-701-000, HOSE WRENCH ASM ............................................................................................................................................................................................................................................................................................. 465

817H 168H
Figure 9-99 EO-4696-700-035, PISTON SEAL INSTALL TOOL ............................................................................................................................................................................................................................................................................. 466

81H 1689H
Figure 10-1 EO-5093-510-002, WB COLOR STACK ARM ASM............................................................................................................................................................................................................................................................................. 469

819H 1690H
Figure 10-2 EO-6102-510-005, P500iA WB COLOR STACK ASM.......................................................................................................................................................................................................................................................................... 470

820H 169H
Figure 10-3 EO-4657-590-005, SOLV/AIR 5 VALVE ASM ...................................................................................................................................................................................................................................................................................... 471

821H 1692H
Figure 10-4 EO-4657-590-000 Sheet 1 of 5, WB VALVE BLOCK ............................................................................................................................................................................................................................................................................ 473

82H 1693H
Figure 10-5 EO-4657-590-006, WB NON-RECIRCULATING VALVE BLOCK ..................................................................................................................................................................................................................................................... 475

823H 1694H
Figure 10-6 EO4657-590-002A, End Block ................................................................................................................................................................................................................................................................................................................. 477

824H 1695H
Figure 10-7 EO-4657-590-003, BSPP Fitting............................................................................................................................................................................................................................................................................................................... 478

825H 169H
Figure 10-8 EO-9999-111-101, PARKER 6x8MM 1/4BSPP FITTING ASSY........................................................................................................................................................................................................................................................... 479

826H 1697H
Figure 10-9 EO-9999-111-103, PARKER 9X12MM 1/4BSPP FITTING ASSY........................................................................................................................................................................................................................................................ 480

827H 1698H
Figure 10-10 EO-9999-111-105, PARKER 7x10MM 3/8NPT FITTING ASSY ........................................................................................................................................................................................................................................................ 481
82H 169H
Figure 10-11 EG-00590 Sheet 1 of 3, PARKER SS FITTING INSTALLATION GUIDELINE ................................................................................................................................................................................................................................ 482
829H 170H
830H 170H
831H 1702H
Figure 10-14 EG-00594 Sheet 1 of 2, PARKER Parklok Check Valve Installation GUIDELINE.............................................................................................................................................................................................................................. 485
832H 1703H
Figure 10-15 EG-00594 Sheet 2 of 2, PARKER Parklok Check Valve Installation GUIDELINE.............................................................................................................................................................................................................................. 486
83H 1704H
Figure 10-16 EG-00595 Sheet 1 of 3, PARKER RIGHT ANGLE ADAPTER KIT INSTALLATION GUIDELINE ............................................................................................................................................................................................... 487
834H 1705H
835H 1706H
836H 170H
Figure 10-19 EO-5093-700-005, FITTING WRENCH................................................................................................................................................................................................................................................................................................ 492

837H 1708H
Figure 10-20 EO-5093-700-017, REGULATOR SEAT TOOL................................................................................................................................................................................................................................................................................... 493

83H 1709H
Figure 10-21 EO-9999-111-701, PARKER FITTING INSTALL ASSEMBLY 8MM ............................................................................................................................................................................................................................................... 494
839H 170H
Figure 10-22 EO-9999-111-702, PARKER FITTING UNINSTALL ASSEMBLY 8MM.......................................................................................................................................................................................................................................... 495

840H 17H
Figure 10-23 EO-9999-111-703, PARKER FITTING INSTALL ASSEMBLY 12MM ............................................................................................................................................................................................................................................. 496
841H 172H
Figure 10-24 EO-9999-111-704, PARKER FITTING UNINSTALL ASSEMBLY 12MM........................................................................................................................................................................................................................................ 497

842H 173H
Figure 10-25 EO-9999-111-705, PARKER FITTING INSTALL ASSEMBLY 250................................................................................................................................................................................................................................................... 498

843H 174H
Figure 10-26 EO-9999-111-706, PARKER FITTING INSTALL ASSEMBLY 250SS .............................................................................................................................................................................................................................................. 499
84H 175H
Figure 11-1 EO-5093-510-001 Sheet 1 of 2, 1K COLOR STACK ARM ASSEMBLY.............................................................................................................................................................................................................................................. 502

845H 176H
Figure 11-2 EO-5093-510-001 Sheet 2 of 2, 1K COLOR STACK ARM ASSEMBLY.............................................................................................................................................................................................................................................. 503

846H 17H
Figure 11-3 EO-6102-510-001, P500iA COLOR STACK ARM ASSEMBLY .......................................................................................................................................................................................................................................................... 504
847H 178H
Figure 11-4 EO-6263-510-001 Sheet 1 of 2, 1K COLOR STACK ASM .................................................................................................................................................................................................................................................................... 505

84H 179H
Figure 11-5 EO-6263-510-001 Sheet 2 of 2, 1K COLOR STACK ASM .................................................................................................................................................................................................................................................................... 506

849H 1720H
Figure 11-6 EO-4657-501-000, SOLV/AIR 3 VALVE ASM ...................................................................................................................................................................................................................................................................................... 507

850H 172H
Figure 11-7 EO-5093-510-013, SOLV/AIR 4VALVE ASM ....................................................................................................................................................................................................................................................................................... 508

851H 172H
Figure 11-8 EO-4657-502-000, COLOR MODULE .................................................................................................................................................................................................................................................................................................... 510

852H 1723H
Figure 11-9 EO-4657-504-000, NON-RECIRCULATING COLOR SLICE............................................................................................................................................................................................................................................................... 512

853H 1724H
Figure 11-10 EO-5093-503-000, REGULATOR ASM................................................................................................................................................................................................................................................................................................ 514

854H 1725H
Figure 11-11 ET-5093-890-006 Sheet 1 of 2, P-700 1K Process Schedules ................................................................................................................................................................................................................................................................ 515

85H 1726H
Figure 11-12 ET-5093-890-006 Sheet 2 of 2, P-700 1K Process Schedules ................................................................................................................................................................................................................................................................ 516

856H 172H
-19-
Figure 11-13
857H ET-5093-890-005 Sheet 1 of 3, 5093 REGULATOR............................................................................................................................................................................................................................................................................ 517 1728H
Figure 11-14
Figure 11-15
Figure 11-16
860H EO-9999-111-105, PARKER 7x10MM 3/8NPT FITTING ASSY ........................................................................................................................................................................................................................................................ 522 173H
Figure 11-17
861H EO-5513-700-003, VALVE TOOL ........................................................................................................................................................................................................................................................................................................ 523
1732H
Figure 11-18
862H EO-5093-700-005, FITTING WRENCH................................................................................................................................................................................................................................................................................................ 523
173H
Figure 11-19
863H EO-5093-700-017, REGULATOR SEAT TOOL................................................................................................................................................................................................................................................................................... 525 1734H
Figure 11-20
864H EO-9999-111-701, PARKER FITTING INSTALL ASSEMBLY 8MM ............................................................................................................................................................................................................................................... 526 1735H
Figure 11-21
865H EO-9999-111-702, PARKER FITTING UNINSTALL ASSEMBLY 8MM.......................................................................................................................................................................................................................................... 527 1736H
Figure 11-22
86H EO-9999-111-703, PARKER FITTING INSTALL ASSEMBLY 12MM ............................................................................................................................................................................................................................................. 528 173H
Figure 11-23
867H EO-9999-111-704, PARKER FITTING UNINSTALL ASSEMBLY 12MM........................................................................................................................................................................................................................................ 529 1738H
Figure 11-24
86H EO-9999-111-705, PARKER FITTING INSTALL ASSEMBLY 250................................................................................................................................................................................................................................................... 530 1739H
Figure 11-25
869H EO-9999-111-706, PARKER FITTING INSTALL ASSEMBLY 250SS .............................................................................................................................................................................................................................................. 531 1740H
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1 VERSABELL II+ APPLICATOR MARMCP7AP07071E REV. C
1 VERSABELL II+ APPLICATOR
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-22-
2 High Voltage Controls MARMCP7AP07071E REV. C
2 HIGH VOLTAGE CONTROLS

2.1 Overview - ITW Ransburg High Voltage Control System
2.1.1 Introduction
The ITW Ransburg High Voltage Controller A12311-00 in conjunction with the Cascade A12295-00 (legacy type) or Cascade A12296-00 (integrated type) is used to provide high voltage for electrostatic application equipment.
The ITW Ransburg High Voltage Controller uses a combination of proven high voltage generation technology microprocessor-based control with diagnostic and communication functions. It uses a variable voltage output to drive a
cascade that amplifies the voltage to a high value. It also uses feedback with both current and voltage information to attempt to maintain actual value at set point. The processor circuitry provides the maximum in applicator transfer
efficiency, while maintaining the maximum safety.
2.1.2 Specifications
2.1.2.1 Environmental / Physical

U
Operating Temperature:
0°C to +55°C
Storage and Shipping: Temperature:

40°C to +85°C
Humidity:
95% Non-Condensing
Physical Size:
5.5" tall X 7.5" wide X 3.5" deep
2.1.2.2 Electrical
U
Power Required:
24VDC ± .5 V @ 2.5 Amps maximum (@ sea level), regulated, with over-voltage protection.
Note: For every 1000 ft. of increased elevation, the maximum current is increased by 3%.
High Voltage Output:

24 Volts, 1Amp Form C relay contact
Controller Operating Range:

High Voltage: 0-100kV, settable in 1kV increments
Current: 0-150 micro amps
Communication Requirements
Control and Reporting: Ethernet IP
NOTE: A unique MAC ID will be assigned for each High Voltage Controller.
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MARMCP7AP07071E REV. C 2 High Voltage Controls
2.1.3 Mounting Dimensions

The ITW HV Controller is intended to be mounted into a cutout of a grounded metal enclosure. This provides display and access to the front panel and protects the rear of the power supply.
Figure 2-1: ITW HV mounting dimensions
2.1.4 System Components

The ITW High Voltage Controller A12311-00 is shown below:
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Figure 2-2: High Voltage Controller Layout
2.1.4.1 Display
U
The front panel displays the high voltage and current output from the cascade as true readings. They are derived from feedback signals in the low voltage cable between the controller and cascade.
2.1.4.2 Switches
U
Power Switch
The rocker switch on the left and the LED directly above it are for power On/Off selection and display. The green LED is on when the power is On to the controller.
Local/Remote Switch
This is used to determine if the Local (Front Panel) controls have priority or it the Remote (Ethernet Connection) controls have priority. If the switch is up (Local Mode) the Front Panel controls may change parameters, enable or disable
the high voltage, and clear faults. The Remote Ethernet connection may look at parameters and values, but may not change them or enable/disable the high voltage output. If the switch is down (Remote Mode) the opposite is true except
that the Front Panel switch may be changed to local mode at any time to disable the Remote Controls and to enable the Local Controls.
HV On/Off Switch
This is a floating toggle switch. It is active if the Local/Remote mode switch is in Local. It is used to enable and disable the High Voltage output and to clear system faults. When the System Checks
and Current Status are OK flipping the switch to the up position (HV On) will enable High Voltage Output. Flipping it to the down position (HV Off) will disable the High Voltage Output. If there is a system fault, flipping this switch to
the OFF position (also known as the Reset position) it will reset (clear) any faults currently detected by the system.
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2.1.4.3 LED indicators

U
Power LED
If the Green Power LED is on, then the system power to the controller is On.
Fault LED
The red Fault LED is lit when the system detects a fault condition. When operating in "Local Mode", it is cleared by flipping the HV On/Off switch to the Off (Reset) position. If the system is still in a fault condition, it will immediately
be lit as the system detects the fault.
High Voltage LED

The green High Voltage LED displays the current state of the High Voltage Output. This LED is illuminated whenever High Voltage is being supplied.
2.1.4.4 Buttons
U
The six buttons used to control the viewing and entry of information on the 4 X 20 character display are:
Screen Button
The Screen Button (at the top) is used to change (toggle) to the next Menu screen. The menu screens wrap around so that after the last screen it will return to the first screen.
Up and Down Buttons

The buttons above and below the Set Button in the middle (the Up and Down Buttons) are used to change which value on the screen is to be changed.
Set Button
This labeled button (in the middle) is used to select the value to change and to enter the change after it has been made.
Increase and Decrease Buttons

The buttons to the right and left of the Set Button are the Increase and Decrease Buttons. They are used to change the value selected by the Set Button.
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2.1.4.5 Connections
U
Figure 2-3: ITW HV controller connections
Input Power Connections

Input power must be supplied from a regulated DC power Supply. The connection is made at J8 with +VIN at 24VDC ± .5V, GND at 24VDC return, CGND at Earth Ground. The 24 VDC supply must be protected against excessive
current as well as
Over Voltage protected.
Note: The ITW Ransburg High Voltage Controller has a built in resettable fuse so if it draws a current in excess of 2.5 amps it will open. Reset is achieved by turning controller power OFF for 5 minutes then back ON.
Ethernet Connector
Use the appropriate 10/100BASE Ethernet wiring (Straight EIA/TIA 568A) for your installation using a RJ-45 plug to connect to the ITW High Voltage Controller.
Interlock Connection
J9 is supplied to give a hardwire connection thru relay dry contacts (rated at 24 VDC @ 1 amp maximum) for when the controller operating power is turned OFF or a fault condition exists. They are marked as COM (Common) NC
(normally closed) or NO (normally open) and can be used by end user.
Output to Cascade Connection

Make connections from J6 of the controller to the cascade per the following table.
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HVC-J6 Cascade
A12295-00 (FRA# EE-4526-800) or
A12296-00 (FRA# EE- 4626-801)
HVGND Pin 1 0 VDC for R+ and E+ Power
R+ Pin 2 Analog DC Cascade Drive Signal
E+ Pin 3 Nominal 15VDC for Cascade Electronics
GND Pin 4 0 VDC for Analog Cascade Voltage Feedback
U-FB Pin 5 Analog Cascade for Voltage Feedback Signal
SC Pin 6 0 VDC for Analog Cascade Current Feedback
I-FB Pin 7 Analog Cascade Current Feedback Signal
Table 2-1: ITW HV Output to Cascade pin detail
RS232 Connection
This connector is a service connection for the ITW Ransburg factory.
2.1.5 Cascades
There are two types of ITW cascades used in FANUC Robotics paint application HV control systems:
The ITW (legacy type - EE-4526-800) cascade is shown below:
Figure 2-4: ITW legacy cascade (EE-4526-800)
The legacy style cascade is used on P-700iA Flex, VersaBell I, and ServoBell application systems. The ITW (integrated type - EE-4526-801) cascade is shown below:
Figure 2-5: ITW integrated cascade (EE4526-801)
The integrated style cascade is used on P-250iA, P-500, P-500iA, and P-700iA (non Flex) application systems.
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2.1.5.1 High Voltage Cables

U
When used with a VersaBell II type applicator, there is a high voltage cable that connects the high voltage generated by the cascade to the paint applicator. This cable has specific lengths used on a particular robot model / configuration.
Figure 2-6: High voltage cable
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HV Cable Assembly #: Robot Model / Configuration:

EE-4696-625-001 P-500
EE-4696-625-002 P-500 Long Arm
EE-4696-625-003 P-700iA
EE-4696-625-004 P-250iA Short Arm
EE-4696-625-005 P-250iA Standard Arm
EE-4696-625-006 P-700iA Flex
EE-4696-625-007 P-500iA Flex Standard Arm
EE-4696-625-008 P-500iA Flex Long Arm
Table 2-2: HV cable assemblies
For High Voltage Cable Installation see Remote mode – High voltage Controller FB-200 HVU section.
2.1.6 Overview - ITW Ransburg High Voltage Control System

The ITW Ransburg High Voltage Controller A12311-00 in conjunction with the Cascade A12295-00 (legacy type) or Cascade A12296-00 (integrated type) is used to provide high voltage for electrostatic application equipment.
The ITW Ransburg High Voltage Controller uses a combination of proven high voltage generation technology microprocessor-based control with diagnostic and communication functions. It uses a variable voltage output to drive a
cascade that amplifies the voltage to a high value. It also uses feedback with both current and voltage information to attempt to maintain actual value at set point. The processor circuitry provides the maximum in applicator transfer
efficiency, while maintaining the maximum safety.
2.2 Operation and Setup – ITW HV Controller
On all of the menus, if there is a parameter that can be changed there are a number of "#" characters to show that it is an enterable value. If there is more than one enterable value, pressing the Up or Down Buttons will move the "#'s" to
the next changeable value. When the "#'s" are next to the value you wish to change, press the Set Button. This will bring up the Password Menu to allow you to enter the password and change the value. Once the password has been
entered, it will remain active for an appropriate amount of time and then time out, requiring you to re-enter it.
When a valid password has been entered for any value (even if the value has not been changed) different menus will be available. These Menus are the Display Contrast Menu, the IP Address Menu, and the Enter New Password Menu.
When a numeric value is being changed (using the buttons to the left and right of the SET Button) the numeric will increase with the right button and decrease with the left button until it passes the maximum or minimum allowed value at
which time it will "roll over" to the other limit.
2.2.1 Start-Up Menu

This is the menu that displays on the unit for 5 seconds (approximately) at power up. It displays the Model Number, Copyright Date, Serial Number, Software Version, and Hardware Version of the unit. It then changes to the Run Menu.
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Figure 2-7: ITW Start-Up Menu
2.2.2 Run Menu

This menu displays the set point (KVSET if in Voltage Mode, uASET if in Current Mode), the current actual KV value, the current uA value, the current hardware check value, the High Voltage status, and the current controller status.
The set point (KVSET or uASET) is the only changeable value on this menu.
Figure 2-8: ITW Run Menu
2.2.3 Mode Menu

This menu displays the current mode (Voltage or Current) and the high and low limits allowed for the Dependent Value in that mode. Consult FANUC Robotics before changing any of these values.
Figure 2-9: ITW Mode Menu
2.2.4 Sensitivity Menu

This menu displays the current di/dt or dv/dt limit value and the enable status for di/dt or dv/dt depending on the mode. Consult FANUC Robotics before changing any of these values.
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Figure 2-10: ITW Sensitivity Menu
2.2.5 Fault Menu

This menu displays the latest fault and is displayed automatically upon the fault detection.
Figure 2-11: ITW Fault Menu
2.2.6 IP Address Menu

This menu allows the setting of the units IP Address. When the new IP Address has been entered, the unit must have the power cycled before the new IP Address will be used.
Figure 2-12: ITW IP Address Menu
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2.2.7 Password Menu

This menu is different in that the "#'s" are displayed below the password digit being changed instead of beside them. When the password is entered, the menu will return to the value being changed.
2.2.8 Enter new Password Menu

This menu is different in that the "#'s" are displayed below the password digit being changed instead of beside them. When the new password is entered, it will now be used for all values being changed.
2.2.9 Parameters and Settings Menu
2.2.9.1 Mode
U
The operating mode can be set to either Voltage or Current mode. The mode selection determines which independent set point is the basis for control.
2.2.9.2 kVSet
U
This is the voltage set point, used in Voltage Mode. The system attempts to keep the voltage at this value.
2.2.9.3 uASet
U
This is the current set point, used in Current Mode. The systems attempts to keep the current at this value.
2.2.9.4 kV Limit Hi
U
This parameter determines the level where a kV Limit Fault occurs. When the voltage falls below this value, it issues a kV limit Fault. It only applies in Voltage Mode. Consult FANUC Robotics
before changing this value.
2.2.9.5 uA Limit Hi
U
This parameter determines the level where a Current Limit Fault occurs. When the current rises above this value, it issues a Current Limit Fault. It only applies in Voltage Mode. Consult FANUC Robotics before changing this value.
2.2.9.6 Di/dt Sensitivity

U
When a rapid current change occurs where current rises faster than this value in approximately 100 ms, it issues a di/dt fault. This is only active in Voltage Mode. Consult FANUC Robotics before changing this value.
2.2.9.7 Dv/dt Sensitivity

U
When a rapid voltage change occurs where voltage falls faster than this value in approximately 100 ms, it issues a dv/dt fault. This is only active in Current Mode. Consult FANUC Robotics before changing this value.
2.2.9.8 Dx/Dt
U
This parameter enables or disables the di/dt or dv/dt fault limits. Consult FANUC Robotics before changing this value.
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2.3 Control Conditions – ITW HV Controller

16B
2.3.1 Power Up
On power up, the system does several checks to determine hardware status. It checks various signals to determine that there are no faults, including feedback from the Variable Voltage Output and High Voltage Inputs to determine
system status. If it determines that it is OK to start, the Check display on the run menu changes from NoGo to OK and System Status changes to OK.
2.3.2 HV On
When the HV On signal is received, the system status changes to "Starting" and the Variable Voltage Output is increased until the Independent Value rises to within a tolerance window (currently +/-3) of the set point value. Then the
System Status changes to "Running".
2.3.3 Set Point Changed

If the set point changes outside the control window, the status changes to "Rising" or "Falling" until the Independent Value again reaches the window at which point it returns to "Running".
2.3.4 HV Off
On HV Off the system immediately sets the Variable Voltage Output to zero volts, disables the HV Relay and goes to Stop Mode. The System Check goes to NoGo until the High Voltage and Variable Voltage Output feedback again
reach the pre-determined value.
2.4 System Status (STS) – ITW HV Controller

2.4.1 OK
System is off and ready to start.
2.4.2 Starting/Rising/Falling
System is changing from one voltage/current value to another. Di/dt and dv/dt checks are disabled.
2.4.3 Running
System is attempting to keep a steady value on Set point (the Independent Value). All enabled checks are active.
2.4.4 Stopping
System is off and waiting to transient voltages/currents to stop.
2.4.5 Warning
System has detected a current or voltage condition within 10% of the limit settings.
2.4.6 Fault
System has detected a fault condition, stopped and will not allow starting until the fault is cleared. If the fault condition has not been cleared, it may immediately fault without starting.
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2.5 System Check (CHK) – ITW HV Controller

2.5.1 OK
System has passed the checks and is ready to start.
2.5.2 NoGo
System has detected excessive voltage on the High Voltage or Variable Voltage Output Feedbacks and will not allow a start.
2.6 Ethernet I/P Interface – ITW HV Controller

The Ethernet IP Interface is defined as a set of four 16 bit IO words of input and a set of four 16 bit words of output.
2.6.1 Ethernet I/P Configuration

2.6.1.1 MAC ADDRESS:
U Unique hard coded by manufacturer, displayed on unit
IP ADDRESS: User settable from front panel
INPUT INSTANCE: 113
INPUT WORDS: 4
INPUT WORD SIZE: 16 bits
OUTPUT INSTANCE: 112
OUTPUT WORDS: 4
OUTPUT WORD SIZE: 16 bits
CONFIG INSTANCE: 100
RPI: 32ms
2.6.2 I/P Address Configuration

1. Turn on the power supply with the rocker switch on the front.
2. Press and release the SCREEN key until the IP address is displayed.
3. Use the up and down arrow keys to select the field to edit.
4. Press SET to be prompted for a password.
5. The password is 4723.
6. Use the up and down arrow keys to select the password digit.
7. Use the right and left arrow keys to scroll through available numeric values.
8. Press SET after each digit is selected.
9. Scroll through and enter the I/P address as needed.
10. Cycle power with the rocker switch after you are finished.
2.6.3 Ethernet I/O

2.6.3.1 Output Words
U
There are 4 output words of 16 bits each mapped to inputs on the robot controller.
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OUTPUT OUTPUT WORD 2 OUTPUT WORD 3 OUTPUT

WORD 1 WORD 4
BIT DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION
0 IN CONTROL Over CURRENT WARNING param data word bit 0 actual KV bit 0
1 RAMPING Over VOLTAGE WARNING param data word bit 1 actual KV bit 1
2 CONTROL OK TO Under VOLTAGE WARNING param data word bit 2 actual KV bit 2
START
3 REMOTE MODE param data word bit 3 actual KV bit 3
4 HV On Echo param data word bit 4 actual KV bit 4
5 Warning param data word bit 5 actual KV bit 5
6 Fault COMM FAULT param data word bit 6 actual KV bit 6
7 H/W FAULT param data word bit 7 actual KV bit 7
8 LOW VOLTAGE FAULT parameter bit 0 actual uA bit 0
9 DV/DT FAULT parameter bit 1 actual uA bit 1
10 DI/DT FAULT parameter bit 2 actual uA bit 2
11 MINIMUM OUTPUT FAULT parameter bit 3 actual uA bit 3
12 MAXIMUM OUTPUT FAULT parameter bit 4 actual uA bit 4
13 OVER VOLTAGE FAULT parameter bit 5 actual uA bit 5
14 OVER CURRENT FAULT parameter bit 6 actual uA bit 6
15 HEARTBEAT CABLE FAULT parameter acknowledge actual uA bit 7
Table 2-3: ITW Output Words
2.6.3.2 Output Bit Details

U
IN CONTROL: The control parameter is within 3KV or 3uA of the set point.
RAMPING: The KV or uA is ramping up or down tot he set point.
CONTROL OK TO START: The power supply is ready for an ENABLE signal.
REMOTE MODE: The REMOTE/LOCAL toggle switch is in REMOTE.
HV ON ECHO: The high voltage is ON.
WARNING: There is a warning present, see warning bits.
FAULT: There is a fault present, see fault bits.
HEARTBEAT: This output is cycled on and off every second.
OVER CURRENT WARNING: Warning active, see Warning section and Troubleshooting section for additional information.
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OVER VOLTAGE WARNING: Warning active, see Warning section and Troubleshooting section for additional information.
UNDER VOLTAGE WARNING: Warning active, see Warning section and Troubleshooting section for additional information.
COMM FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
H/W FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
LOW VOLTAGE FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
DV/DT FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
DI/DT FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
MINIMUM OUTPUT FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
MAXIMUM OUTPUT FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
OVER VOLTAGE FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
OVER CURRENT FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
CABLE FAULT: Fault active, see Warning section and Troubleshooting section for additional information.
PARAM DATA WORD BIT 0-7: Used to tell the system the value of a parameter.
PARAMETER BIT 0-6: Used to tell the system which parameter is being displayed.
PARAMETER ACKNOWLEDGE: Used to acknowledge a parameter read or write request.
ACTUAL KV BIT 0-7: Real time feedback of the voltage at the output of the cascade.
ACTUAL UA BIT 0-7: Real time feedback of the current draw from the output of the cascade.
2.6.3.3 Input Words

U
There are 4 input words of 16 bits each mapped to outputs on the robot controller.
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INPUT WORD INPUT WORD 2 INPUT WORD 3 INPUT WORD 4

1
DESCRIPTION DESCRIPTION DESCRIPTION DESCRIPTION
0 HV ENABLE KV Set Point word bit 0 param data word bit 0

1 RESET FAULT KV Set Point word bit 1 param data word bit 1
2 CURRENT MODE KV Set Point word bit 2 param data word bit 2
3 KV Set Point word bit 3 param data word bit 3
8 uA Set Point word bit 0 set param bit 0 request param bit 0
15 uA Set Point word bit 7 set param strobe request param strobe
Table 2-4: ITW Input Words
2.6.3.4 Input Bit Details
U
HV ENABLE: Enables high voltage if conditions are OK at the rising edge.
RESET FAULT: The rising edge clears any fault that no longer exists.
CURRENT MODE: Turned OFF for Voltage mode and ON for Current mode.
KV SET POINT WORD BIT 0-7: The voltage setting in voltage mode or the voltage ceiling in current mode.
UA SET POINT WORD BIT 0-7: The current set point in current mode.
PARAM DATA WORD BIT 0-7: The data word used to set parameters.
SET PARAM BIT 0-6: The parameter number to be set.
SET PARAM STROBE: The indication to set the indicated parameter to the specified value.
REQUEST PARAM BIT 0-6/REQUEST PARAM STROBE: The parameter to be read and the read request.
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2.6.4 Ethernet I/O Parameter Configuration

There are 10 parameters to control power supply performance accessible via Ethernet I/O. Consult FANUC Robotics before changing any of these values.
PARAMETERS
DESCRIPTION READ/W U DEFAULT MIN MA
RITE NI VALUE VAL X
TS UE VAL
UE
1 DV/DT LIMIT READ/WRITE KV/100ms 16 3 24
2 DI/DT LIMIT READ/WRITE uA/100ms 40 8 50
3 V-MAX READ/WRITE KV 103 20 103
4 I-MAX READ/WRITE uA 80 10 150
5 V-MIN READ/WRITE KV 0 0 80
6 DX/DT ENABLE READ/WRITE n/a 1 0 1
7 USER PW DIGIT 1 READ ONLY n/a 0 0 9
Table 2-5: ITW Ethernet I/O Parameter Configuration
2.6.4.1 TO READ A PARAMETER:

U
1. Set input word 4 bits 8-14 to indicate the desired parameter

2. Set input word 4 bit 15 to request the parameter
3. Output word 3 bit 15 will come on
4. Read output word 3 bits 8-14 to verify you are getting the requested parameter
5. Read output word 3 bits 0-7 to get the parameter data
6. Reset input word 4 bit 15
7. Output word 3 bit 15 will turn off
8. Reset input word 4 bits 8-14
2.6.4.2 TO WRITE A PARAMETER:

U
1. Set the data for the parameter on input word 3 bits 0-7
2. Set the parameter to change on input word 3 bits 8-14
3. Set the parameter strobe on input word 3 bit 15
4. The parameter acknowledge on output word 3 bit 15 will turn on
5. Reset the parameter strobe on input word 3 bit 15
6. The parameter acknowledge on output word 3 bit 15 will turn off
7. Reset the data for the parameter on input word 3 bits 0-7
8. Reset the parameter to change on input word 3 bits 8-14\
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2.7 Manual Operation – ITW HV Controller
2.7.1 Front Panel Display
Table 2-6: ITW Boot up screen
Table 2-7: ITW Voltage mode status
Table 2-8: ITW Current mode status
2.7.2 Local Mode

1. Turn the power supply rocker switch to ON.
2. Turn the LOCAL/REMOTE toggle switch to LOCAL.
3. Move the cursor to the Voltage or Current, depending on the operating mode.
4. Press SET to select the data field.
5. Use the right and left arrow keys to set the desired value.
6. Press SET to select the value.
7. Use the HV ON/OFF toggle switch to turn on and off the electrostatic voltage/current.
8. Should a fault occur, select HV OFF momentarily to reset the fault.
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2.8 Remote Operation – ITW HV Controller

2.8.1 Voltage Mode
1. See Section 2.6.2 to set the Ethernet I/P address as desired.
3. Turn the LOCAL/REMOTE toggle switch to REMOTE.
4. Initiate Ethernet I/P communication from the host.
5. See FAULT RESET to clear any fault.
6. Set the requested estat voltage level on input word 2 bits 0-7.
7. The estats will be energized when ENABLE(input work 1 bit 0) goes hi if OK TO START(output work 1 bit 2) is on.
8. Voltage feedback can be read from output word 4 bits 0-7.
9. Current feedback can be read from output word 4 bits 8-15.
10. The set voltage and enable may be changed at will.
2.8.2 Current Mode

1. See Section 2.6.2 to set the Ethernet I/P address as desired.
3. Turn the LOCAL/REMOTE toggle switch to REMOTE.
4. Initiate Ethernet I/P communication from the host.
5. See FAULT RESET to clear any fault.
6. Set CURRENT MODE(input word 1 bit 2).
7. Set the requested estat voltage ceiling on input word 2 bits 0-7.
8. Set the requested estat current level on input word 2 bits 8-15.
9. The estats will be energized when ENABLE(input work 1 bit 0) goes hi if OK TO START(output work 1 bit 2) is on.
10. Voltage feedback can be read from output word 4 bits 0-7.
11. Current feedback can be read from output word 4 bits 8-15.
12. The set voltage and enable may be changed at will.
2.8.3 Fault Reset

1. Clear the opportunity that caused the fault.
2. Read the fault bits(input word 2 bits 6-15)
3. Reset the ENABLE(input work 1 bit 0).
4. Set FAULT RESET(input word 1 bit 1)
5. Reset FAULT RESET(input word 1 bit 1)
2.9 Maintenance and Repair

2.9.1 Cautions and Warnings
See ITW High Voltage Controller Manual LN-9623-00 for specific safety precautions.
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2.9.2 Replace ITW Controller

1. Press and release the SCREEN key repeatedly until the IP address is displayed
2. Write down the IP address
3. Turn off the HV Controller
4. Unplug the Power, Network, cascade, and optional fault contact connectors
5. Disconnect any ground or shield tied to the chassis
6. Unbolt and remove the HV Controller
7. Insert the new HV Controller and fasten in place with appropriate hardware
8. Attach ground or shield connections to the chassis
9. Turn off the HV Controller
10. Plug in the Power, cascade, and optional fault contact connectors
11. Switch the HV Controller to LOCAL
12. Turn on the HV Controller
13. Scroll through the menus with the SCREEN key to set the IP address (password: 4723)
14. Switch the HV Controller to REMOTE
15. Reboot the HV Controller
16. Scroll through the menus to verify the correct IP address
17. Connect the network cable
18. Reset the communication, verify with the COMM status indicator on the HV Controller
19. Use the Teach Pendant to perform a HV Controller parameter RESET TO DEFAULT
20. Run a ghost job to verify operation
2.10 Troubleshooting
2.10.1 Fault Descriptions
• The system has detected a communication failure after an Ethernet IP connection was initiated.
• An out of range data was sent to the HV Controller over remote I/O.
• The HV Controller has detected a fatal system error. Replace HV Controller.
• In current mode, the power supply has detected a feedback voltage lower than KV LIMIT LO. Check the setup for KV LIMIT LO.
• In current mode with DX/DT enabled, the measured rate of voltage rise over time has exceeded the DV/DT limit.
• In voltage mode with DX/DT enabled, the measured rate of current rise over time has exceeded the DV/DT limit.
• The power supply detects an actual voltage or current greater then zero with no command voltage.
• The power supply has attained the maximum command voltage and the set point could not be achieved. The system has raised the Variable Voltage Output to the system maximum, but could not reach the set point.
• The measured feedback voltage of the cascade has exceeded the KV LIMIT HI setting.
• The measured feedback current of the cascade has exceeded the uA LIMIT HI setting.
• The system has detected a loss of the High Voltage Feedback signal from the cascade which should always be from 4mA to 20mA.
• The system has detected a loss of the Current Feedback signal from the cascade which should always be from 4mA to 20mA.
2.10.2 Warning Descriptions

• The measured feedback current of the cascade is approaching the uA LIMIT HI setting.
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• The measured feedback voltage of the cascade is approaching the KV LIMIT HI setting.
• In current mode, the power supply has detected a feedback voltage approaching the KV LIMIT LO setting.
2.10.3 PaintTool Alarm Codes

ALARM # ALARM DESC. CAUSE REMEDY
PNT1-949 ESTAT Over uA warning While operating in Voltage mode the current draw is within Possible sources include: dirty applicator covering, a
10% of the limit. line not blown out during color change, or applicator
too close to part being processed.
PNT1-950 ESTAT Over KV warning The actual Voltage is within 10% of the internal safety limit. Possible sources include: dirty applicator covering, a
line not blown out during color change, or applicator
PNT1-951 ESTAT Under KV warning While operating in current mode, the load is so great that the Possible sources include: dirty applicator covering, a
voltage is within 110% of the low threshold. line not blown out during color change, or applicator
PNT1-955 ESTAT H/W fault A serious internal fault has occurred, or the High Voltage was Verify the voltage was not enabled during a fault and
enable while a Fault existed. replace the power supply.
PNT1-956 ESTAT Comm. fault One of the parameters was sent to the power supply out of the Review the process setup and verify parameters are
expected range. used within their range limits.
PNT1-957 ESTAT Low KV fault While operating in current mode, the applicator draws so much Possible sources include: dirty applicator covering, a
current that the power supply was not able to attain a minimal line not blown out during color change, or applicator
KV value. too close to part being processed.
PNT1-958 ESTAT DV/DT fault While operating in Current mode with DX/DT enabled, the rate Possible sources include: dirty applicator covering, a
of voltage rise over time exceeded the DV/DT set point. line not blown out during color change, or applicator
PNT1-959 ESTAT DI/DT fault While operating in Voltage mode with DX/DT enabled, the Possible sources include: dirty applicator covering, a
rate of current rise over time exceeded the DI/DT set point. line not blown out during color change, or applicator
PNT1-960 ESTAT Min. output fault Either Voltage or Current feedback has been detected with the Check cable(s) between the power supply and
minimum output of the power supply. cascade, replace the cascade.
PNT1-961 ESTAT Max. output fault Either Voltage or Current feedback was not able to reach the Check cable(s) between the power supply and
set point before reaching the maximum output of the power cascade, replace the cascade.
supply.
PNT1-962 ESTAT Over KV fault The KV feedback from the cascade has exceeded the internal Review the application to verify the limit is set
safety limit or the parameter KV limit. correctly. Clean applicator and adjust the path as
needed.
PNT1-963 ESTAT Over uA fault The KV feedback from the cascade has exceeded the parameter Review the application to verify the limit is set
uA limit. correctly. Clean applicator and adjust the path as
needed.
PNT1-964 ESTAT Cable fault Either a short circuit or open circuit has been detected with the Check the cable(s) from the power supply to the
voltage or current feedback circuit from the cascade to the cascade to verify insulation has not been
power supply. compromised.
Table 2-9: ITW PaintTool alarm codes
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2.11 Spare Parts

2.11.1 Spare Parts
Part Number Description Replacement Period
EE-4526-300 High Voltage Controller A12311-00 Upon failure
EE-4526-800 Cascade A12295-00 (legacy Upon failure
type)
EE-4526-801 Cascade A12296-00 (integrated Upon failure
type)
EE-4696-625-XXX High Voltage Cable – Robot 4000 Hours
configuration specific lengths.
See Table 2-2 for table of robot
model specific HV cable lengths.
Table 2-10: ITW spare parts list
2.12 Overview – High voltage Controller FB-200 HVU

2.12.1 Introduction
The High Voltage Control Unit (FB 200-HVU) controls electrostatics for the FANUC Robotics America VersaBell I, VersaBell II and ServoBell applicators.
This Operating Manual must be read, fully understood and observed in all respects by all persons who are responsible for the devices and the electrostatic installation. For these reasons the Operating Manual should always be available to
the operating, maintenance and service personnel.
Only with the knowledge of this Operating Manual faults can be avoided and a trouble-free operation guaranteed. Therefore it is important that the Operating Manual is known to all persons involved. FANUC Robotics North America,
Inc. (in the following called FRNA) will not assume any responsibility resulting from the failure to comply with the Operating Manual!
2.12.2 Specifications
2.12.2.1 Environmental / Physical

U
Temperature / Humidity:
The HV control unit FB 200-HVU may only be used in electrostatic coating installations within the temperature range of 15°C to 45°C and a relative humidity of between 10% to 70% (non-condensing).
Physical Size:
Dimensions H/W/D 3 U / 42 HP / 175mm
Serial number see label
Year of construction see label
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2.12.2.2 Electrical
U
Power Required:
Input voltage: 85-265V AC, singe phase
Input frequency: 47- 63Hz
Input current: 1A
Max. power dissipation: 20 W
High Voltage Output:

Output voltage: 0 – 24V DC
Output current: max. 2A
Controller Operating Range:

Constant Voltage Operation
High voltage: 0-100kV adjustable in single kV-steps
Static current switch off: 0-275µA adjustable in single µA-steps
High voltage ramp rate: 1-250kV/s adjustable in single kV/s-steps.
The actual ramp rate is limited by the capacity of the HV-system and is approximately <100kV/s
Constant Current Operation

Current: 0-275µA adjustable in single µA-steps
Max. voltage limitation: 0-100kV adjustable in single kV-steps
Min. voltage limitation: 0-100kV adjustable in single kV-steps
High voltage ramp rate: 1-999µA/s adjustable in single µA/s-steps.
2.12.3 Mounting / Installation
ATTENTION!
The high voltage control unit must be mounted into a grounded 19” Rack. The backplane has to be screwed onto the back of the rack with ten metric 2.5 x 8mm screws.
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Figure 2-13: High voltage system components
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After having switched on the main switch, the start-up display appears for 5 seconds, monitoring the hardware and software version. “HW:” displays the hardware version, while”SW:” displays the software version.
Figure 2-14: High voltage start up screen
After 5 seconds, the main display appears.
Figure 2-15: High voltage main menu
Line 1 of the main window displays the safety check status and the operating mode. 'OK' indicates safety check has passed and 'NOK' means the safety check failed . 'U-Operat.' is Voltage Operating mode and 'I-Operat.' is Current
operating mode. Line 2 displays the set value for voltage in kV and current in µA. Line 3 displays the actual value for voltage in kV and current in µA. Line 4 shows the condition of HV (HV-OFF, HV-Enable and HV-ON), shows
which step is selected, and provides access to the E-stat setup parameters. Note: Steps are explained in detail in section 2.2.
Local / Remote Switch

The Local / Remote Switch determines which operator interface has control over the HV Controller. In Local mode, the front panel controls the operation of the HV Controller. In Remote mode, the wired connections to the robot I/O
have control over the operation of the HV Controller.
HV Enable Key Switch

The HV Enable switch is used to enable high voltage output from the HV Controller when the unit is in Local mode. This is a momentary switch; the high voltage remains enabled after the switch has been released.
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Figure 2-16: High voltage controller LED indicators
Main Power Switch

The Main Power Switch enables 120V AC to the DC power supplies located inside the HV Controller chassis. Pressing the button will retain the button in the ON position. The lamp inside the button will illuminate. Pressing the button
again will shutoff power to the HV Controller and the illuminated light will shutoff.
HV Disable Button
HV Disable button is used to disable high voltage output from the HV Controller in Local mode. The HV disable is a momentary button that returns to position after it is released.
Cursor Buttons
The Cursor buttons are used to scroll through menu items and select them.
Numeric Keypad Buttons

The Numeric Keypad buttons are used to input numbers 0 – 9. The ESC button is used to escape out of a menu item. The arrow button is used as an “Enter” button. When a menu item is to be modified, press the arrow button to enable
the value to be modified. Enter the new data via the 0 – 9 buttons, then press the arrow button again to set the new parameter data.
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2.12.5 Backplane Connections
Figure 2-17: High voltage backplane
2.12.5.1 Main
U
The power requirements state specific voltage levels for line 1 (85-265VAC) and neutral (0VAC), an ungrounded system may either split the voltage or reverse it.
CON 120 / Main

Description Signal
Single phase input 1 85-265V AC
Neutral 0V AC
Protection Ground PE GND
Table 2-11: High voltage controller main ac power pin detail
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2.12.5.2 Generator
U
X 166 / HV-GEN
Pin Description Signal Generator Wire color
GND Ground GND Pin 1 White
R+ Power 0-24V DC Pin 2 Red
E+ Electronic supply 15V DC Pin 3 Blue
SHLD Shield GND Pin 4 Orange
U-FB Feedback voltage 4-20mA Pin 5 Yellow
SC Safety check 0-20mA Pin 6 Black
I-FB Feedback current 4-20mA Pin 7 Brown
Table 2-12: High voltage Output to Cascade pin detail
2.12.5.3 Digital Outputs

U
Table 2-13: High voltage digital output pin detail
• For using the digital Outputs with the internal supply (24V DC) connect pin ‘24V’ with Pin ‘V out’ and pin ‘G out’ with pin ‘GND’.
• For using the digital outputs with an external supply (24V DC) connect pin ‘V out’ with 24V DC from the external supply. If it is necessary to have potential free outputs don’t connect pin ‘Gout’ with pin ‘GND’.
• The digital outputs are separable from internal ground and from internal 24V DC with bridge in two blocks.
• Output voltage: 15-24V DC externally supplied or 24V DC + 5/-10% internally supplied.
• Output current: 100mA over-current protected, switch-off at 350mA
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N°. Description Function Indicators

1 HV-ON High, if the high voltage is on or if the unit senses any Display set point and
stored energy above a safe level actual V and I
2 HV-Set point High, if a value pre-set from 0 to 100% is achieved. LED green (HV-arrow)
reached In the V-mode V and in the I-mode I.
3 HV-Warning High, if a value pre-set from 0 to 100% of the LED yellow
statically switching-off is achieved.
4 HV-Fault High, if a dynamically or statically switching-off LED red
happens. Display
5 Ground switch High, if the HV is switched on and is adjustably
triggered from 0 to 100s.
6 Check OK Low, if the safety check has not been fulfilled. (see Display “Check OK” -
Remaining Energy Time section) or- “Check NOK”
7 Remote/Local High if the unit is in remote mode
Mode
8 Rem.Energ.OK Low if the allowed remaining energy is too high (see
Capacity section)
Table 2-14: High voltage digital output discriptions
2.12.5.4 Digital Inputs

U
Table 2-15: High voltage digital input pin detail
• If it isn’t necessary to have potential free inputs connect pin ‘Gin’ with ‘GND’.
• The digital inputs are separable from internal ground and from internal 24V DC with bridge in two blocks
• Input voltage: 24V DC + 20%, H-level > 13V.
• Input current: Max. 10mA @ 29V DC / each channel
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N°. Description Function

1 HV-ON External signal to switch on the high voltage in the
remote mode
2 V/I-Operating High = I-mode, Low = V-mode
mode
3 Unused Unused
4 Safety check High = Start signal for the safety check (rising edge)
5 Unused Unused
6 Steps bit 1 To realize 8 steps Binary 1
Table 2-16: High voltage digital input descriptions
2.12.5.5 Analog outputs

U
X165 / ANA-Out
Pin Description Signal Range
1 I-Actual 0-10V DC 0V = 0uA
GND Ground GND 10V = 307.2 uA
2 U-Actual 0-10V DC 0V = 0V
GND Ground GND 10V = 100kV
3 I-Actual 4-20mA 4mA = 0uA
GND Ground GND 20mA = 307.2 uA
4 U-Actual 4-20mA 4mA = 0kV
GND Ground GND 20mA = 100kV
Table 2-17: High voltage analog output pin detail

1 I - actual Readout of the actual value for the current 0 – 10V DC / 1 K Ohm
2 V- actual Readout of the actual value for the voltage 0 – 10V DC / 1 K Ohm
3 I- actual Readout of the actual value for the current 4-20 mA / 250 Ohm
4 V- actual Readout of the actual value for the voltage 4-20 mA / 250 Ohm
Table 2-18: High voltage analog output descriptions
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2.12.5.6 Analog inputs

U
X164 / ANA-In
Pin Description Signal Range
1 I-Set point 0-10V 0V = 0uA
GND Ground GND 10V = 307;2 uA
2 U-Set point 0-10V 0V = 0V
GND Ground GND 10V = 100kV
3 I-Set point 4-20mA 4mA = 0uA
GND Ground GND 20mA = 307.2 uA
4 U-Set point 4-20mA 4mA = 0kV
GND Ground GND 20mA = 100kV
Table 2-19: High voltage analog input pin details
To command voltage or current using 0 - 10 Volts (Analog Input channels 1 and 2), 4-20 milliamps (Analog Input channels 3 and 4), or Step Bits (Digital Inputs 2, 3, and 4 on X161) set the dip switch settings on the back plane as
follows:
Table 2-20: High voltage dip switch settings

1 I-set point Set point for the HV operating voltage 4-20 mA 249 Ohm
2 V- set point Set point for the HV operating current 4-20 mA 249 Ohm
3 I-set point Set point for the HV operating voltage 0-10 V >100 kOhm
4 V- set point Set point for the HV operating current 0-10 V >100 kOhm
Table 2-21: High voltage analog input descriptions
2.12.5.7 Sub-D 9 connectors
U
SIO1 unused
CAN1 unused
FLASH1 For Software update via serial cable (not crossed)
Ethernet 10BaseT RJ45 connection
2.12.5.8 Ethernet connection

U
Integrated protocols: TCP/UDP/ IP socket, FTP

Help protocols: ARP, RARP, DHCP/BOOTP, PING, RIP
2.12.6 Cascades
There are two types of high voltage cascades used in FANUC Robotics paint application HV control systems.
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Figure 2-18: High voltage legacy cascade (EO-4526-110-000)
The legacy style cascade is used on P-700iA Flex, VersaBell I, and ServoBell application systems. The integrated style cascade is used on P-250iA, P-500, P-500iA, and P-700iA (non Flex) application systems.
Figure 2-19: High voltage integrated cascade (EE-4696-800)
2.12.7 High Voltage Cables

When used with a VersaBell II type applicator, there is a high voltage cable that connects the high voltage generated by the cascade to the paint applicator. This cable has specific lengths used on a particular robot model / configuration.
Figure 2-20: High voltage cable
HV Cable Assembly #: Robot Model / Configuration:

EE-4696-625-001 P-500
EE-4696-625-002 P-500 Long Arm
EE-4696-625-003 P-700iA
EE-4696-625-004 P-250iA Short Arm
EE-4696-625-005 P-250iA Standard Arm
EE-4696-625-006 P-700iA Flex
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EE-4696-625-007 P-500iA Flex Standard Arm

EE-4696-625-008 P-500iA Flex Long Arm
Table 2-22: High voltage cascade assemblies
2.13 Operation and Setup – High voltage Controller FB-200 HVU

2.13.1 Select Language
The cursor appears in the display by selecting one of the cursor-buttons. To change the displayed language, select one of the cursor-buttons and the 'ESC' button at the same time. English is the default language and German is the
secondary language.
2.13.2 Parameter Edit Mode

When the cursor is on a value than can be changed, the edit mode is achieved by activating the ‘Return’ push button. When in edit mode, all the LED’s are activated. When 'Return' is selected, the old value first changes to 0. The new
value may be entered from the numeric key pad. Values such as On/Off, and I/U, may be changed with the right and left cursor push buttons. Pushing ‘ESC’ while in Edit mode cancels the change and returns the previous value. Pushing
‘Return’ stores the new value.
2.13.3 Setup
To enter Setup mode, cursor to 'Setup' and by press ‘Return’. The Setup window displays the parameters which can be changed with the current password level assigned. In the ‘Parameter-Assignment’ the plant administrator may
determine which parameter may be changed with respect to the password level assigned. The default set point values for U and I for step X are visible without password entry.
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The first line shows the active window and the Setup window navigation. An arrow to the right of the ‘E’ means that the next window is opened by pressing the right cursor. An arrow to the left of the ‘E’ means that the next window is
opened by pressing the left cursor.
2.13.4 Passwords
To enter a password, enter 'Setup' mode and select the right cursor until the ‘Additional’ setup window is displayed. The cursor automatically moves onto ‘Set User’. Press the ‘Return’ button. The user is prompted to enter a password.
Depending on the security level of the password entered, different variables are available for edit.
2.13.5 Assigning Passwords

The plant administrator with the administrative password has the opportunity to set all passwords and to activate the parameter assignment.
Passwords are assigned by selecting ‘Passwords’ from the 'Setup Additional' screen. Cursor to the password level to modify and change the password using the procedure described in Operation and Setup – High voltage section, Press
‘ESC’ to return to the 'Additional' window.
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2.13.6 Parameter Assignment

Select ‘Parameter-Assignment’ to assign the password level to edit a parameter.
The global administrator assigns a password level for each parameter. There are five password levels that can be assigned: No password needed, Normal User (1), Advanced User (2), Plant Administrator (3), and Global Administrator
(G). To change the security level for a variable, cursor to the variable and select 'return'. Use the arrow keys to position the '+' key to the appropriate level. If there is not a '+' selected, the parameter may be changed by anybody without a
password. The "Default val. KV" parameter above is an example of this. In the ‘Default Imax uA’ variable, the '+' is under the 1. This means password level 1 or higher (2,3,G) is required to change this parameter. When the ‘+’ is
underneath the ‘2’, a password level 2, 3 or G is required to edit variables. When the ‘+’ is underneath the ‘3’ a password level, 3 or G is required. Only Global Administrators can edit variables where 'G' is selected. Press ‘ESC’ to return
to the 'Additional' window.
2.13.7 Paintworks Parameter Access

The High Voltage parameters can also be viewed from the PaintWorks "Estat Parameters" screen. The Estat Parameters screen is shown below. Press the scroll bar to the left of the parameters to view additional parameters.
2.13.8 Step Mode Settings
The Step Mode window is displayed by selecting 'Setup' from the main screen and navigating through the various 'Setup' windows.
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This screen is to assign the voltage and current set-point values and to select the operating mode for Steps 1 through 7. Change the value using the procedure described in Parameter Edit Mode of the Operation and Setup – High voltage
section. Note: Only Step 7 is available for the common user to edit. Please consult FANUC Robotics America, Inc if alternate step settings are required.
2.13.9 Parameter Security

The Parameter Security window displays all parameters relevant for the safety of the system. The screen is displayed by selecting 'Setup' from the main screen and navigating through the various 'Setup' windows.
2.13.10 Pre-warning
The Pre-Warning is the percentage of the switch-off threshold that the warning appears. For example, if in U-operation the I-static-switch-off value is 100 µA, the warning is set when the current reaches 20% of the value (80µA). The
warning is set in I-operation at 20% before U-Min is achieved. The pre-warning is shown by the ‘Pre-warning’ LED and the discrete output ‘HV-warning’ is activated.
2.13.11 Release
The Release % is the percentage of the set-point value where the 'Set Point Reached' signal is set. For example, if the set point in U-operation is 100kV, the set point reached signal is set at 90% of the value (90 KV). The release is shown
by the ‘Set Point Reached' LED and the discrete output ‘HV set-point reached’ is activated.
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2.13.12 Locking
The Locking Time (in seconds) is a pre-adjusted time delay for the discrete output ‘Ground switch’ after switching off the HV. The output ‘Ground switch’ is activated with ‘HV-ON’ and is deactivated with HV-OUT plus the duration
of the Locking Time.
2.13.13 Plant Safety
The Plant Safety setting is the voltage at which it is safe for humans work with the High Voltage unit.
ATTENTION,. This value depends on the total capacity of the plant and whether the cleaning is done with solvent-containing agents.
It has to be adjusted according to the safety standards applied.
A value of 0-100kV may be entered. After the High Voltage unit is switched off, the output ‘HV-ON’ remains activated until the actual KV is below the Plant Safety value.
2.13.14 Capacity
Each plant may be used to store electrical energy (like a battery). If a discharge happens, an energy results from this capacity and the voltage. Here the plant capacity to calculate the energy supervision necessary may be adjusted.
2.13.15 Remaining Energy
Remaining Energy is the electrical energy held by the system at a given moment. The remaining energy may be adjusted to the maximum energy allowed when it is permissible to be touched. According to EN 50176 the maximum
energy allowed is 350mJ before contact is permitted. However, if the cleaning is done with solvent-containing agents the maximum permitted energy is 0.24mJ, which, in principle, is the energy which might combust solvent. A value
from 0.01 mJ to 600.00 mJ may be entered.
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2.13.16 Calculated momentum voltage
The Eq. Moment. kV shows the value calculated from the remaining energy (2.13.14) and the capacity. This value is the maximum permissible value upon touching the bell/diffuser in order not to surpass the adjusted energy (2.13.15) at
the pre-adjusted capacity.
2.13.17 Remaining Energy Time
The Remaining Energy Time is the time required by a person to enter a spray booth and touch the bell/diffuser. The worst case (shortest time) is when the cabin door is opened, how long it will take the user to touch the bell/diffuser. The
HV-control automatically supervises if the actual kV value is higher than the specified Remaining Energy after the Remaining Energy Time has passed.
2.13.18 Safety check
The safety check is an automatic test of the Imax switch off. A safety check can be initiated by the controller before HV-ON (rising edge of HV-ON, value set to 1) or after HV-ON (falling edge of HV-ON, value set to 0). If the value is
preset to 2 the test must be initiated by hand or the PLC. When the test runs the high voltage is disabled. The test needs around 2 seconds to complete. If the safety check is successful, the display will show ‘Check OK’ and the discrete
output ‘Check OK’ is set to high. If the safety check is not achieved the display will show ‘Check NOK’ and the discrete output ‘Check OK’ is set to ‘low’.
2.13.19 Parameter Controller
The Parameter Controller window displays all parameters needed for the control of the system. The screen is displayed by selecting 'Setup' from the main screen and navigating through the various 'Setup' windows.
SEE DEFAULT PARAMETERS SECTION FOR DEFAULT PARAMETERS VALUES.
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2.13.20 Default U kV
The default value for the output voltage may be adjusted from 0-100kV. The value is permanently stored and is available when the supply voltage is powered on, but it is only used for Step X (local) operations.
2.13.21 Default I µA
The default value for the output current may be adjusted from 0 to 27µA. The value is permanently stored and is available when the supply voltage is powered on, but it is only used for Step X (local) operations.
2.13.22 Default Operation
In this line, the default operating mode may be adjusted between I-operation and U-operation. The operating mode is being stored and is valid after switching on the supply voltage, but ins only relevant for step X (test operation).
2.13.23 Imax switch off
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1. Imax switch off accounts for the static current switch-off in Voltage operation. If the Imax switch-off stands on 'ON', the HV-control switches off once the operating current has reached the pre-adjusted set value. If an Imax switch-
off happens, the digital output 4 ‘HV-fault’ is activated, the red LED ‘Fault’ lights up and the display shows the fault. The static current switch-off may be de-activated in this line with the input mode (see 2.13.2), the display than
shows ‘Imax switch Off Off’. Once the operating current has reached the pre-adjusted set value with switched-off Imax, the voltage is regulated back.
2.13.24 Max. +di/dt µA/s
In this line the value for the dynamic current switch-off from 0 to 999 µA/s (only in U-operation) may be adjusted with rising current, which is a positive edge. This means if the current rises faster than the value adjusted in this line, the
HV-control switches off. With a dynamic current switch-off the digital output 4 ‘HV-fault’ is activated, the red LED ‘Fault’ lights up and the display shows the fault. The dynamic current switch-off may be deactivated as described in
2.13.24.
2.13.25 +di/dt Check
Here the input mode for supervising the positive current edge (see 2.13.23) - +di/dt.- may be deactivated.
ATTENTION: This value is a safety relevant parameter and may only be handled by trained personnel.
2.13.26 Max. -di/dt µA/s
In this line, the value for the dynamic current switch-off from 0 to 999 µA/s (only with U-operation) in case of a power failure, that is with a negative current edge may be adjusted. That means, if the current is reduced faster as the pre-
adjusted value at this time, the HV-control is switched-off. With a dynamic current switch-off the digital output 4 ‘HV-fault’ is activated, the red LED ‘Fault’ lights up and the display shows the fault. The dynamic current switch-off may
be deactivated as described in 2.13.23
2.13.27 -di/dt Check
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Here the input mode (see 2.13.2) may be used to deactivate the supervision of the negative current edge – di/dt.
2.13.28 Umin kV
Umin switch-off stands for the static voltage switching-off from 0 to 100 kV in I-operation. The HV-control switches off if the operating voltage is regulated back to the previously adjusted set value. With a Umin switch-off, the digital
output 4 ‘HV-fault’ is activated, the red LED ‘Fault’ lights up and the display shows the fault. The static current switch-off may be adjusted in this line with the input mode and may deactivated as described in 2.13.28.
2.13.29 Umin switch off
Here with the input mode (see 2.13.2) the static voltage switch-off in I-operation may be deactivated. If the voltage switch-off in I-operation is deactivated, the voltage isn’t regulated back anymore upon reaching the set value but is kept
constant.
2.13.30 Max. +dU/dt µA/s
In this line the value for the dynamic voltage switch-off from 0 to 999 kV/s (only in I-operation) may be adjusted if the voltage increases, i.e. with a positive edge. That means, if the voltage rises faster that the value set at this time, the
HV-control switches off. With a dynamic voltage switch-off the digital output 4 ‘HV-fault’ is activated, the red LED ‘Fault’ lights up and the display shows the fault. The dynamic current switch-off may be deactivated as described in
2.13.24.
2.13.31 +dU/dt Check
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Here with the input mode (see 2.13.2) the supervision of the positive current edge +dU/dt may be deactivated.
2.13.32 Max. -dU/dt µA/s
In this line the value for the dynamic current switch-off from 0 to 999 kV/s (only in I-operation) upon reducing the voltage, i.e. with negative edge, may be adjusted. That means if the voltage is reduced faster than the value pre-adjusted
in this line, the HV-control switches off. With a dynamic voltage switch-off the digital output 4 “HV-fault” is activated, the red LED “fault” lights up and the display shows the fault. The dynamic current switch off may be de-activated
as described in 2.13.26.
2.13.33 -di/dt Check
Here with the input mode (see 2.13.2) the supervision of the negative current edge –dU/dt. may be de-activated.
2.13.34 U-Run-Up kV/s
In this line with the input mode (see 2.13.2) the run-up ramp from 0 to 250 kV/s for U-operation may be adjusted. 250kV/s is the maximal value, i.e. the faster run-up time is only a theoretical value as this would conform to a run-up time
of 0-100kV in 0,4s. The run-up time depends on the total capacity of the spray system. Values up to 100kV/s are realistic. With low capacities a run-up time 0-100kV of 0.7s approx. may be possible which corresponds with a value of
143kV/s approx.
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2.13.35 I-Run-Up µA/s
In this line with the input mode (see 2.13.2) the run-up ramp from 0 to 999µA/s for I-operation may be adjusted.
2.13.36 dX/dT Averages (For Display Only)

The dX/dT Averages is the number of samples of the current and voltage feedback the controller will monitor before determining there is a high voltage fault. The value for dX/dT Averages is set to 50. Each sample is approximately 5
ms. After the initial 50 samples, the HV Controller drops the oldest sample and performs fault control on the most recent 50 samples.
2.13.37 Ana. Input Ch.

The Analog Input Channel setting specifies which group of Analog Inputs the controller is monitoring for remote voltage or current command. Channels 1&2 are voltage inputs and Channels 3&4 are current inputs. The default value is 3
(Channels 3&4)
2.13.38 Act. I Output

The Actual Current Output setting specifies which HV Controller Analog output channel the actual current feedback is displayed on. The default is 4 which is the HV Controller AO Channel 1 (Voltage).
2.13.39 Max-I load % (only software 1.21f or higher)

Voltage operation only
Max-I load limits the current used during voltage ramp-up. A value of 100% disables this function. To enable Max-I load, use value lower than 100%. A good value for a plant must be found by testing with different values at the plant.
50% - 70% are reasonable values. This feature is designed to control the voltage ramp on a high capacitance (water based) systems to reduce the number of IMAX (over current) faults.
Operation: If the actual current is higher than the percentage of the Max-I load the voltage is reduced, the voltage ramp-up is slowed or stopped until the current returns to a value lower than ‘Max-I load ‘. There is an internal delay
provoked by averaging the values in the HV controller, so the current can be higher than the value set by Max-I load before the voltage is reduced. Imax switch off is not disabled in this time. If an over current or other fault occurs,
for example by a spark, the high voltage is switched off.
For example, the Voltage set point is 50 KV and 60 uA. The Max I Load % is set to 50%. During the ramp, the current rises quickly over 30 uA. Instead of continuing the ramp and potentially having an IMAX fault, the software will
stop the Voltage ramp until the current is below 30 uA.
2.13.40 Count I load (only software 1.23f to 1.23Fc)

This variable defines the number of cycles (one cycle is approximately 5ms) that the current limiter operates. After the count is exceed, the ‘Max-I load’ switches off and the run up ramp for high voltage is stopped. Also, the digital
output ‘HV-fault’ is activated, the red LED ‘Fault’ indicator is on, and the ‘V-Ramp stopped’ alarm message is displayed on the main screen. The purpose of this feature is to prevent the entire vehicle from being sprayed with low High
Voltage because the system is constantly operating with the current limited. The value for this field is 0 – 999 counts.
Note: In the 1.23F and 1.23Fc software, there is a software bug that causes the Count I Load not to work if the value is greater than 125. This software problem was fixed with version 1.23Fd and enhanced with the time based I Load
Time Out in version 1.23fE.
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2.13.41 I load Time Out (only software 1.23Fe)
This variable defines the time (seconds) that the current limiter operates when the Max I Load% is enabled. After the actual time that current limiter is invoked exceeds this variable, the ‘Max-I load’ switches off and the run up ramp for
high voltage is stopped, the digital output ‘HV-fault’ is activated, the red LED ‘Fault’ indicator is on, and the ‘V-Ramp stopped’ alarm message is displayed on the main screen.
The purpose of this feature is to prevent the entire vehicle from being sprayed with low High Voltage because the system is constantly operating with the current limited. The valid values for this field are 0 – 99.9 seconds. If the Max I
Load% is enabled and the I Load Time Out is 0, the HV Controller ignores the time and will run continuously in current limiter mode. The timer for the current limiter is reset each time the HV On signal is commanded on and each time
the Step command changes (1). If the I Load Time Out time is longer than the spray time for a single High Voltage command, the V Ramp alarm will not occur.
2.13.42 I-max off (only software 1.23f or higher)

When enabled, I Max off limits the current in voltage mode (without faulting) when the current exceeds the I-max set point for the commanded voltage. But the high voltage will still shut off if the actual current is higher than ‘I-max off’
value. This feature allows the system to run in fold back mode but with all the safety checks still enabled. This function is helpful on water base plants to compensate temporary over currents. This feature is enabled by setting the value
higher than 0μA. The valid values for I-Max off are 0-275 μA. To properly use this function, the value for I-Max Off should be higher than the I-Max set point.
Example: The preset value is 80 KV and 90 uA. The maximum value for I-Max is 150 uA. If the actual current exceeds 90 uA, the system will limit the voltage until the current drops below 90 uA. This is know a fold back mode and
operates similar to current mode. However, the system will still fault if there is a sharp current rise that exceeds 150 uA.
2.14 Default Parameters – High voltage Controller – FB-200 HVU

Below is a listing of the default parameters as of version 1.25f0:
Default
Solventborne Default Waterborne Default Waterborne
Inde Value Value Value
x (Defaults) P-500 / P-700 P-200 Description
1 0 0 0 Default val. kV
2 100 100 100 Default val. uA
3 0 0 0 Default Operat.
4 16 16 16 Imax switch off
5 300 300 300 Max.+dI/dt uA/s
6 1024 1024 1024 +dI/dt Check
7 300 300 300 Max.-dI/dt uA/s
8 0 0 0 -dI/dt Check
9 15 15 15 Vmin kV
10 32 32 32 Vmin switch off
11 100 100 100 Max.+dV/dt kV/s
12 0 0 0 +dV/dt Check
13 100 100 100 Max.-dV/dt kV/s
14 0 0 0 -dV/dt Check
15 20 20 20 Prewarn. (+/-)%
16 10 10 10 Release %
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17 30 30 30 Locking s
18 10 10 10 Plant Safety kV
19 50 50 50 Capacity nF
20 24 24 24 Rem.Energy mJ
21 97 97 97 Eq. Moment. kV
22 90 90 90 Step 1: V kV
23 100 100 100 Step 1: I uA
24 0 0 0 Step 1: Operat.
25 85 85 20 Step 2: V kV
26 95 95 100 Step 2: I uA
28 80 80 25 Step 3: V kV
29 90 90 100 Step 3: I uA
31 70 70 30 Step 4: V kV
32 80 80 100 Step 4: I uA
34 60 60 35 Step 5: V kV
35 70 70 100 Step 5: I uA
37 50 50 50 Step 6: V kV
38 60 60 100 Step 6: I uA
40 40 40 40 Step 7: V kV
41 50 50 100 Step 7: I uA
43 50 25 25 V-Run-Up kV/s
44 50 25 25 I-Run-Up uA/s
45 0 0 0 Rem.En. Time s
46 2 2 2 Safety Check
47 0 0 0 Step 0:V kV
48 50 50 50 Step 0: I uA
49 50 50 50 dX/dt averages
Analog Input
50 3 3 3 Channel
Actual Current
51 4 4 4 Output
52 100 50 50 Max I Load
53 0 100 100 Timeout I Load
54 0 0 0 I-Max Off uA
55 2 2 2 Step 0 Mode
Table 2-23: High voltage default parameter settings
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2.15 Manual Operation – High voltage Controller – FB-200 HVU

2.15.1 Local Mode
2.15.1.1 Step X
U
Step X is reserved for testing operations in local mode only. Values adjusted in this mode are not stored. After switching off and on the power supply, these values are reset to the default values. Step X default values are set in the Setup
Mode.
Switching over the operating mode in step X

With the cursor buttons one may move the cursor onto the ‘U’ of voltage operation. Pressing ’Return’ toggles the operating mode from voltage to current operation.
Figure 2-21: High voltage Step X
Adjusting the set point value kV in step X

With the cursor buttons, move to the ‘set value’ for kV. Press the ’Return’ button to enter edit mode. Change the value using the procedure described in Parameter Edit Mode section.
Figure 2-22: High voltage set voltage
Adjusting the set-point value µA in step X

With the cursor buttons, move to the ‘set value’ for µA. Press the ’Return’ button to enter edit mode. Change the value using the procedure described in Parameter Edit Mode section.
Figure 2-23: High voltage set current
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2.15.1.2 Activate HV in local mode

U
By turning the key switch ‘HV enable’ in local mode, the HV-OFF display changes to HV-On. The HV is now activated.
Figure 2-24: High voltage local mode key switch
Figure 2-25: High voltage high voltage controller unit in Step X mode
‘Act. Value’ shows the actual values. Shortly before the set value is reached, the ‘Set Point Reached' LED is activated.
Note: HV can be activated without the key switch enabled via the external remote signal when the unit is in remote mode.
De-activate HV in local mode

To de-activate the HV, push the ‘HV disable’ button.
Figure 2-26: High voltage HV disable button

2.15.1.3 Step selecting in local mode
U
To change the step, cursor to the ‘Step X' input, as shown in Figure 21. Press the ’Return’ button to enter edit mode. Use the cursor to select the step and press return. Step values from 1 to 7 can be selected. The step 1 to 7 values for
current set-point, voltage set-point and operating mode are stored in Setup. Step X is used when manually selecting the Set values. Step 0 is used only in remote mode for external analog control or if high voltage is disabled.
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2.16 Remote mode – High voltage Controller FB-200 HVU

2.16.1 Step selection
Via the inputs 6 to 8, the steps 0 to 7 may be binary selected in the remote mode as follows:
Input 1 Input 2 Input 3

Step 0 0 0 0
Step 1 0 0 1
Step 2 0 1 0
Step 3 0 1 1
Step 4 1 0 0
Step 5 1 0 1
Step 6 1 1 0
Step 7 1 1 1
Table 2-24: Binary table of high voltage steps
For steps 1 to 7 the pre-set points are adjustable via the front keys as described in 2.13.7. Step 0 uses the analog inputs 1 – 4. In U-operation the voltage pre-set point is given by analog input 2 (0-10V) or 4 (4 – 20mA). In I-operation the
current pre-set point is given by analog input 1 (0-10V) or 3 (4 – 20mA). The pre-set point for Imax resp. Umin are adjustable in step mode (see 2.13.7)
2.16.2 Selecting the operating mode in step 0

The operating mode is selected via digital input 2 “V/I-Operating mode”. High = I-mode, low = V-mode.
2.16.3 Activate high voltage in remote mode.

The high voltage is activated via the digital input 1 “HV-ON”. High = HV-ON, low = HV-OFF.
2.16.4 Start safety check in remote mode.

Via digital input 4 “Safety Check” the safety check is started. For details to the safety check, please see 2.13.17. To start, an impulse is sufficient.
2.17 Maintenance and Repair – High voltage Controller FB-200 HVU

2.17.1 HV Cable Installation
This documents the procedure to replace the Electrostatic High Voltage cable on the P-250, P-500, and P-700 robots. The P-500 robot is used as an example, but the operations are fundamentally the same. This guideline has been
developed to ensure maximum cable life, prevent damage to the robot and process hardware, and safeguard personnel performing the task.
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2.17.1.1 HV Cable Installation Procedure

U
1. Obtain the appropriate replacement cable. See table in the Overview ITW section.
2. Run the Super Purge Cycle to clean out the applicator and lines.
3. Position the robot outer arm so it is accessible with J4, J5, and J6 near 0° (Only J4 and J5 if P-500 robot). This unwinds the process bundle through the wrist to allow ease of installation and promotes maximum cable/hose life.
4. Remove and lockout all sources of hazardous energy to the entire robotic cell.
5. Remove robot over spray covers if applicable.
6. Remove the outer arm hard cover to expose the High Voltage Cable if applicable.
Figure 2-27: P-500 HV cable
7. Use a spanner wrench to remove the applicator. P-500 Robot applicator shown for example.
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Figure 2-28: P-500 applicator quick disconnect
8. Loosen the two bolts in the process bundle clamp.
Figure 2-29: P-500 process bundle clamp
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9. Loosen the cord grip and remove the HV Cable from the cascade.
Figure 2-30: P-500 HV cable / cascade connection
10. Locate and remove the part number label from the tubing on the High Voltage cable that will be removed. The clearance between the tubing and the hole through the quick disconnect will not allow the label to pass.
Figure 2-31: HV cable part number label
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11. Pull the HV Cable out through the applicator QD plate. Put the part number tag back on if sending the cable to FANUC Robotics.
Figure 2-32: HV Cable in applicator QD Figure 2-33: HV Cable pulled through applicator QD
12. Remove the part number label from the tubing on the new cable, save to reapply.
13. Verify the hose bundle is not crossed or tangled as it runs through the wrist and outer arm.
14. Feed the new HV Cable through the applicator QD and into the arm.
Figure 2-34: HV cable inside of robot wrist
15. Feed the HV Cable under the tubing clamp in the center of the process bundle.
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Figure 2-35: HV cable fed back through process bundle clamp
16. Feed the HV Cable through the cord grip and into the cascade. The white insertion gauge should remain half exposed when the cable is fully inserted.
Figure 2-36: HV cable / cascade connection
17. Tighten the cord grip on the cascade to 120 in/lbs.
18. Tighten the two bolts on the outer arm process bundle clamp to 11 in/lbs.
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Figure 2-37: Process bundle clamp bolt position
19. Reapply the part number label to the nylon tube covering the HV cable between the outer arm clamp and wrist.
Figure 2-38: HV cable part number position
20. Apply Dielectric grease to the applicator and HV Cable petticoats. Be careful not to get grease on the metal pin or socket.
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Figure 2-39: Dielectric grease locations
21. Reinstall the applicator using the spanner wrench.
22. Reinstall the outer arm cover.
23. Reinstall robot over spray pajamas if applicable.
24. Perform manual HV Tests below and then run “Ghost” simulation jobs to confirm that the new HV Cable is operating correctly.
• Reset the system in Manual mode and send the applicator shaping air shroud clear of all grounded metal.
• From the GUI Fluid Maintenance screen, run a High Voltage test at 60KV(step5) for 60 seconds.
Verify the voltage feedback is within 5KV of the set point and the current feedback is less than 5uA.
• Move the applicator shaping air shroud within 50-100mm(2-4”) of a well grounded metal object.
• From the GUI Fluid Maintenance screen, run a High Voltage test at 60KV(step5) for 60 seconds. Verify the voltage feedback is within 5KV of the set point and the current feedback is greater than 10uA. Current draw
may be excessive and cause an I-max or di/dt fault.
Table 2-25: High voltage test positions and conditions
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2.17.2 Legacy Cascade Maintenance - Greasing Procedure

This procedure is used for legacy style cascades used on VersaBell Applicators, ServoBell Applicators, and P-700 Flex Application systems.
For used cascades, clean all old grease out of the cascade petticoat area using cotton swabs. When clean of all grease use an alcohol moistened swab to remove any residual grease. Wipe off the outer cascade body with clean rags and
wipe clean with an alcohol moistened clean rag or pad to remove remaining grease. Let dry.
Figure 2-40: Clean grease locations
New Cascades:
Wipe all areas with provided alcohol pad.
21. Anytime a cascade is replaced, clean all old grease out of the cascade petticoat area in the manifold using cotton swabs. When clean of all grease use an alcohol moistened swab to remove any residual grease. Let dry.
Figure 2-41: High voltage petticoat location
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22. Cover the HV-contact and petticoat area with a light coat of dielectric grease. Use only the recommended grease (Polytac #2) and not Vaseline. Use a small brush to apply a light coat to the petticoat area. The area must be covered
100%. Too much grease will not allow for proper seating of the cascade in the applicator. The appropriate amount of grease is shown below.
Figure 2-42: Dielectric grease applied to a cascade
Figure 2-43: Fanuc Robotics dielectric grease
23. Cover the outside diameter from the metal area to two inches to the front of the cascade with a VERY LIGHT coat of dielectric grease. The area must be covered 100%. Do not cover the metal area or the low voltage connector with
any grease. Too much grease will not allow for proper seating of the cascade in the applicator.
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Figure 2-44: Cascade dielectric locations
24. Install the cascades into the manifold. Tighten the cascade holding screw and than cover the outside diameter with a VERY LIGHT coat of dielectric grease. The area must be covered 100%. No gaps. Too much grease will not
allow for proper seating of the cascade in the applicator.
2.17.3 Integrated Cascade Maintenance

The P-500iA, P-700iA (non-Flex) and P-250iA integrated cascades do not require the application of any dielectric grease to be applied. Grease SHOULD NOT be applied into the well of the high voltage cable.
Figure 2-45: Cascade loaction for NO dielectric grease
2.18 Troubleshooting – High voltage Controller FB-200 HVU

2.18.1 HV Control Unit Alarms
The following faults are displayed on the High Voltage Controller:
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2.18.1.1 Switched-Off because of CABLE-BREAK

U
This fault indicator appears if a wire fails, i.e. has broken or is not connected on the cable between power supply and cascade. The high voltage is switched off and the “HV-fault” is activated. The HV controller can detect three different
CABLE-BREAK conditions, both of the feedback signals and for R+. After the CABLE-BREAK is a text character (I,U, or R). The descriptive text character is displayed for software version 1.21f and later. This character indicates on
which wire the cable-break was detected.
Possible causes are:

1. Cause: A broken low voltage wire section between the high voltage power supply and the cascade.
Remedy: Ring out the wiring for continuity and replace the broken wire or cable. See the appropriate diagram below for cable
locations in your particular system. Refer to the system electrical prints for wiring functionality.
2. Cause: A loose connection at the one of the low voltage terminal strips for one of the low voltage cables.
Remedy: Check screw connections on all terminal strips, this includes the Phoenix connector within the Robot FRP unit in the P200E and Amphenol connector in the P500.
3. Cause: A loose or damaged connection/pin at the cascade low voltage connector.

Remedy: Check the pins to see if they are bent or broken or the solder joint is loose. Attempt to straighten/solder or replace the pins if bent, if broken on the cascade replace the cascade.
4. Cause: A loose/ broken connection at the high voltage power supply back-plane,
Remedy: Check all wires to see if they are properly connected into the terminal strips and are correctly tightened.
5. Cause: Cascade holder bolts are loose causing intermittent connection of the cascade to the connector.
Remedy: Tighten the bolts
6. Cause: VersaBell applicator or cascade in VersaBell not properly tightened allowing the cascade connection to the connector to be marginal.
Remedy: Tighten the applicator using the correct spanner wrench.
7. Cause: In P500 systems only, the cascade holder connection nut within in the FRP unit has loosened causing an intermittent and marginal electrical connection.
Remedy: Remove the black cascade holder from the FRP, check the connection nut for tightness. If loose use Loctite 242 sealant on the threads and tighten properly.
8. Cause: A defective high voltage cascade.

Remedy: Remove the cascade and replace with a new one.
2.18.1.2 Switched-Off because of dV/dt-FAULT

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This fault indicates the rate of current change (in Voltage operation) is rising faster than expected. The high voltage is switched off and the “HV-fault” is activated.

1. Cause: Applicator covers are built up with excessive paint overspray.
Remedy: Change the cover.
2. Cause: Clean washed covers vs. new covers were placed on the applicator and faults occurred.
Remedy: Replace with unwashed covers and contact cover suppler for non-conductive covers.
3. Cause: Distance between the applicator bell cup and/or shaping air assembly is too close to a vehicle.
Remedy: Check for the following possible situations and/or problems and correct it:
a) Vehicle is skewed in the booth on the carrier. Check the vehicle and skid tolerance.
b) Check that the proper job is in the booth.
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c) Vehicle skid is bent. Tag skid for repair.

d) Vehicle may have slipped on the conveyor and is not being tracked correctly.
e) Vehicle gas door is open or out of position
f) Vehicle door or tailgate is open or out of position.
g) Door clip or fixture is out of position and is too close to applicator.
h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between vehicle bell cup and side of the shaping air assembly.
i) Path preset step value was changed (increased) without regard to target distance.
j) Step setting values may have been changed. Compare to original values.
k) Booth humidity too high. Adjust if possible.
l) Paint resistivity is too high. Check the paint kitchen to see if new paint or solvent was added to the paint tanks. High aluminum flake content may cause problems.
m) Applicator had excessive solvent used for cleaning and may have seeped between the applicator components.
n) Paint leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
o) Solvent leak in wrist. Check for a loose connection, electrostatic pin-holing or broken hose.
p) Wash line is not properly purged with air after a color change. Check the purge cycle to insure it is blown down.
q) One of the paint valves is leaking either externally or internally.
r) Possible electrical noise from improper shield or ground connections.
2.18.1.3 Switched-Off because of dI/dt-FAULT

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This fault indicates the rate of current change (in Voltage operation) is rising faster than expected. The high voltage is switched off and the “HV-fault” is activated.

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2.18.1.4 Switched-Off because of EXCEEDING POWER DISSIPATION

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This fault indicates exceeding power dissipation of the HV-generator. If this fault indicator appears, the HV-generator is defective or is overheated. The high voltage is switched off and the “HV-fault” is activated.
1. Cause: The cascade is defective.

Remedy: Replace the cascade.
2.18.1.5 Switched-Off because of OVERLOAD (Vmin)

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This fault indicates the Voltage is below the minimum allowed for the requested current. The high voltage is switched off and the “HV-fault” is activated.

h) Path may have been adjusted and is now too close to the vehicle. Target should be 1 inch per 10KV + 1 inch between
vehicle bell cup and side of the shaping air assembly.
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2.18.1.6 Switched-Off because of OVERLOAD (Imax)

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This fault indicates that the operating current has exceeded the maximum allowed value for the requested Voltage. The high voltage is switched off and the “HV-fault” is activated.

4. Cause: Cascade holder bolts or cascade connector is loose causing an intermittent connection of the cascade to the connector
Remedy: Tighten the bolts or estat cable connector nut. Apply Loctite 242 sealant to prevent loosening.
5. Think about using points Max-I load (3.13.49) and I-max off (2.13.32) on water based systems.
2.18.2 PaintTool HV Alarms

The following faults are displayed on the Teach Pendant and GUI Alarms screen:
2.18.2.1 PAIN-351 "Estat controller warning"

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Cause: The FB-200-HVU High Voltage Controller detected a Warning. This indicates a potential system fault that is not yet at the fault level.
Remedy: Check the status screen on the FB-200-HVU High Voltage Controller. Monitor for conditions such as high current or low voltage while painting that may cause the warning to occur.
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2.18.2.2 PAIN-352 "Estat controller fault"

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Cause: The FB-200-HVU High Voltage Controller detected a fault. The FB-200-HVU sends this fault signal to the robot controller so that all painting is stopped.
Remedy: Check the operator console GUI for a fault and/or fault status on the panel and display of the FB-200-HVU High Voltage Controller. If the fault is not displayed on the GUI after 5 seconds check the FB-200 HVU display for
fault details.
2.18.2.3 PAIN-353 "Estats disabled"

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Cause: The Estat Disconnect Switch is off or the Enable Key Switch on the FB-200-HVU High Voltage Controller is off.
Remedy: Turn the Disconnect switch to ON or turn the FB-200-HVU High Voltage Controller, Enable Key Switch to ON.
2.18.2.4 PAIN-354 "Estat controller not in remote"

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Cause: The Local / Remote Rotary switch on the FB-200-HVU High Voltage Controller is in the Local Mode.
Remedy: Turn the toggle switch on the FB-200-HVU High Voltage Controller to the REMOTE mode.
2.18.2.5 PAIN-355 "Estat HVON Failed"

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Cause: This is a real alarm not a nuisance, when the message occurs the paint job quality is poor due to no high voltage present at the applicator. The root cause of the problem is that the robot controller sent the HVON signal to the FB-
200-HVU High Voltage Controller but did not get a signal back indicating it received the signal. The HV On Alarm is a PaintTool generated alarm not an actual high voltage alarm from the FB-200 HVU High Voltage Controller. When
the robot controller commands voltage, the robot controller turns on the HV ON output that is wired to the FB-200-HVU High Voltage Controller input. The FB-200 HVU High Voltage Controller sends the voltage command to the
cascade when it receives the HV ON signal. When the FB-200-HVU High Voltage Controller senses any energy in the system, it turns on the HV ON output that is wired to the input card in the robot controller. When PaintTool turns on
the HV ON output, it looks for the HV ON input echo from the FB-200-HVU High Voltage Controller. If it does not get the signal after a predetermined time (HVON Input Timeout), the robot controller issues a Warning.
Remedy: Confirm that this is a real problem by monitoring the display on the FB-200-HVU High Voltage Controller. If the step value is between 1 and 7 and the HV ON signal is on and the Actual KV value is 0, then there is a problem
in the system. To debug this problem, start by looking at the FB-200 HVU High Voltage Controller. If the HV On signal is on only when there is a valid step command and the feedback is correct, look at the pendant and confirm the
Digital Input HV ON signal is on. For the P-500 check (DI 257 (Eq1) DI 385 (Eq2)). For P-155 and P-200 compare with another robot to check these Digital Input Signals as many configurations are possible. If any signals are missing,
check the wiring to the I/O card and back plane. If this doesn't clear the problem, start checking ALL the cable connectors and terminal connections associated with the low voltage wiring of the high voltage system.

1. Cascade is defective.
2. Defective high voltage cable (purple) from the cascade to the applicator.
3. Problem with FB-200-HVU High Voltage Controller.
4. Problem with wiring on FB-200-HVU High Voltage Controller back plane or FANUC I/O card (HV ON signal or step signal) in the robot controller cabinet.
5. Defective robot controller I/O card.
6. The FB-200 High Voltage Controller not seeing feedback from the cascades(cable / wiring problem)
7. The FB-200 High Voltage Controller not commanding Voltage (cable / wiring problem - see cable break fault)
8. No Step command with HV ON command. Possible causes are: The preset is set to an invalid value, a wiring problem exist, or the step I/O was mapped incorrectly at the robot controller).
2.18.2.6 PAIN-356 "Estat set point not reached"*

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*Note:
PaintTool V5.30-1 to V6.22-1
PAIN-356
PaintTool V6.31-1 to V7.30-1
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PNT1-678 (Eq1)
PNT1-691 (Eq2)
Cause: The set point reached signal from the FB-200-HVU High Voltage Controller was not received by the robot controller within the appropriate time limit.
Remedy: Check the voltage and set point reached light on the FB-200-HVU High Voltage Controller. The system may be having trouble reaching the requested voltage. If not adjust the set point reached time out setting.
2.19 Spare Parts – High voltage Controller FB-200 HVU

2.19.1 Spare Parts
Part Number Description Replacement
Period
PWRSO000000052O SCHNIER #FB-200-HV V1.25 UNIT Upon failure

EO-4526-110-000 Cascade #810230 (legacy type) Upon failure
ALT: EE-4526-800 ALT: ITW A12295-00 (legacy type)
Note:
To use ITW cascade with Schnier HV Controller,
then Schnier V1.16 software is required. Other
hardware modifications may be required. Contact
FANUC Robotics.
EE-4526-801 Integrated Cascade Upon failure
ALT: EE-4526-801 ALT: ITW A12296-00 (integrated type)
Note:
To use ITW cascade with Schnier HV Controller,
then Schnier V1.16 software is required. Other
hardware modifications may be required. Contact
FANUC Robotics.
EE-4696-625-XXX High Voltage Cable – Robot configuration specific 4000 Hours
lengths. See Overview ITW section for table of
H870U UH
robot model specific HV cable lengths.
Table 2-26: Spare parts and replacement schedule
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3 Bell Speed Control System MARMCP7AP07071E REV. C
3 BELL SPEED CONTROL SYSTEM

3.1 Overview
3.1.1 Introduction
The Bell Speed Control System adjusts the pressure of the drive air supplied to the turbine in order to maintain the commanded bell speed. The closed-loop control of this system is provided by the PaintTool software. Bell speed is
monitored by the fiber optic feedback system. This feedback is used to determine what adjustments need to be made to the I/P regulator on the turbine drive air in order to control turbine speed. An air brake is used to quickly reduce
speed or stop the turbine when necessary.
The fiber optic feedback also allows the software to monitor and report problems with the Bell Speed Control System. Abrupt changes in bell speed, slow transition between set-points, turbine over-speed, and insufficient turbine speed
are all diagnosed and reported as faults and warnings by the Bell Speed Control System.
The components in the fiber optic feedback system are calibrated at assembly. The cruise speed (or idle speed) of the turbine is set at assembly.
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MARMCP7AP07071E REV. C 3 Bell Speed Control System
3.1.2 System Components – Block Diagram Overview
These components are in the Process Control Enclosure (PCE)
Digital
Output
(Brake)
Analog
Robot Output Brake (air)
Solenoid Turbine
Controller (turbine
Turbine Drive (air)
pressure) I/P Regulator
Light signal (fiber optic)

Analog Frequency Keyence Optical
Input Converter Voltage pulses Sensor Unit
(turbine Pulsed light reflected
speed) from encoder (fiber
optic)
• Turbine is driven by air.

• Air pressure for turbine drive is commanded by robot
controller.
• Fiber optic system measures speed of spinning turbine and
provides feedback for closed loop control
• Brake is air driven also.
• Braking air is commanded when actual speed is higher than
command speed.
Figure 3-1: D/Q PCE Block Diagram
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These components are in the Process Control Enclosure (PCE)
Digital
Output
(Brake)
Analog
Robot Output Brake (air)
Solenoid Turbine
Controller (turbine
Turbine Drive (air)
pressure) I/P Regulator
Light signal (fiber optic)

Analog Keyence Optical
Input Voltage pulses Sensor Unit
(turbine Pulsed light reflected
speed) from encoder (fiber
optic)
• Turbine is driven by air.

• Air pressure for turbine drive is commanded by robot
controller.
• Fiber optic system measures speed of spinning turbine and
provides feedback for closed loop control
• Brake is air driven also.
• Braking air is commanded when actual speed is higher than
command speed.
Figure 3-2: Flowmeter Block Diagram Overview
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Figure 3-3: P-500iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview
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Figure 3-4: P-500iA Process Control Enclosure with Air Flowmeter – Bell Speed Control Components
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Figure 3-5: P-500iA D/Q Process Control Enclosure – Bell Speed Control Components
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Figure 3-6: P-700iA 1k Arm with VersaBell II Applicator – Bell Speed Control Components Overview
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Figure 3-7: P-700iA Process Control Enclosure with Air Flowmeter – Bell Speed Control Components
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Figure 3-8: P-700iA D/Q Process Control Enclosure – Bell Speed Control Components
3.2 Operation and Setup

The following sections describe the installation of the components of the Bell Speed Control System and any software setup that is required for this system.
3.2.1 Pressure Regulator (I/P)

The I/P (analog input to pressure) is an electronically controlled pressure regulator that is used to control the turbine drive air. The Pneumatic Control System receives the command signal from the PaintTool application in the robot
controller and transmits this signal to the I/P. The I/P adjusts the turbine drive air pressure according to the command. The pressure is increased in order to increase turbine speed or in response to increased load. The pressure is
decreased in order to decrease turbine speed or in response to decreased load.
3.2.1.1 Installation
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The Festo I/P is mounted by two 4mm screws that attach to a mounting plate through holes in the body of the device.
Figure 3-9: Festo MPPE (TDUCO000000004O) - Turbine Drive I/P
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The SMC I/P is mounted by a quantity of 4 4mm screws that attach to a mounting bracket that attaches to the PCE mounting plate through holes in the underside of the body of the device.
Figure 3-10: SMC ITV 2050 (TDUCO000000019O) - Turbine Drive I/P
The electrical cable connects the I/P to an analog output on the Pneumatic Control System. The turbine supply hoses connect to the supply fitting and deliver air from the air supply manifold. The turbine drive hoses connect to the outlet
fitting and deliver regulated air to the turbine drive ports at the applicator. The exhaust hose connects to the exhaust fitting, and directs the I/P exhaust to the exhaust manifold.
The I/P requires no other setup.
3.2.2 Fiber Optic Sensor (O/E)

The O/E (optical to electrical convertor) emits a light beam to one element of the fiber optic cable. The light is reflected off of an indicator wheel in the turbine that has alternating reflective and non-reflective sections. The reflected
light is transmitted back up the other element of the fiber optic cable to the receiver in the O/E. The O/E then converts the reflected light pulse to an electrical voltage pulse and outputs this chain of pulses to the Frequency Converter
(F/I). The O/E display shows current value (CV) of the received light intensity in red (0-4095) and the preset valve (PV) in green.
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The O/E is mounted to a DIN rail by a snap-on connector. To install the O/E hook the fixed side of the device over the lip of the DIN rail and push the end in the direction of arrow 2 until a snapping sound indicates the connector is
engaged. To remove the O/E from the rail, push the device in the direction of arrow 1 and then pull off the rail in the direction of arrow 3.
Figure 3-11: O/E Installation
Install the optical fibers as shown in Figure 3-12. Open the dust cover in the direction of arrow 1. Move the fiber lock lever in the direction of arrow 2. Ensure that the ends of the optical fibers are free of dust and debris. Insert an
optical fiber into each of the insertion holes to the depth of the fiber insertion sign on the side of the device (approximately 14mm). Return the fiber lock lever to its original position by moving it in the direction of arrow 4. Close the
dustcover.
Dust Cover
Fiber Lock lever
Figure 3-12: Optical Fiber Insertion
The electrical connection to the O/E is permanently attached to the device. Terminate the ends of this cable in the Frequency Converter (F/I) as indicated by the electrical schematic. For process I/O systems that include an air flowmeter,
the Keyence sensor is connected directly to a frequency counter input that is part of the EX600 process I/O rack. See Figure 3-5 or Figure 3-8.
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3.2.2.2 Setup
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The O/E has a number of functional modes. The procedures below are used to setup the proper mode for use in the Bell Speed Control System. These procedures are performed during assembly at FRA and are only required if the O/E is
replaced.
3.2.2.3 Preset Valve Programming

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The O/E requires calibration to establish the levels of light and dark regions on the indicator in the turbine. Level Calibration is set during assembly and should only be necessary if the O/E is replaced. To set the Level Calibration, open the dust
cover as shown in Figure 3-12. Change the Preset Value (PV) to 1400 by pressing the manual button in the direction indicated to increase or decrease the value displayed in green.
Figure 3-13: O/E Level Setting

Mode Selection
The O/E should be set to the following settings for use in the Bell Speed Control System:
• Access mode: EASY
• Power mode: FinE
• Timer function: toFF
These parameters are set during assembly. If parameters are inadvertently changed, they can be restored with the following procedure. If an O/E is changed, the following procedure should be completed to ensure that the O/E functions
as expected.
Figure 3-14: O/E Mode selection
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1. Press the mode button for at least 3 seconds then use the manual button to select ‘EASY’ mode.
2. Press the mode button again and then use the manual button to select ‘FinE’ mode.
3. Press the mode button again and then use the manual button to select ‘toFF’.
4. Press the mode button again to exit the mode selection menu.
Key Lock
The function keys on the front of the O/E can be locked so that accidental inputs do not change settings. To lock the function keys, simultaneously press the mode and manual buttons for at least 3 seconds. The display will read ‘Loc’
when the keys have been locked. To unlock the keys simultaneously press the mode and manual buttons for 3 seconds again.
Figure 3-15: O/E key lock display
3.2.3 Frequency Converter (F/I)

The F/I device measures the frequency of the pulse chain from the O/E and converts it into an analog signal that reports the turbine speed to the control system. For a CPX based configuration, the F/I is a standalone unit that converts a
frequency based signal from the O/E to a 4-20 mA signal. For EX600 based systems, there is no need for a F/I device, as the EX600 has an counter input module that accepts the O/E electrical pulses and converts them to a frequency
count reading that is transmitted over the Ethernet/IP connection to the robot controller.
The F/I is mounted to a DIN rail by a snap-on connector. To install the F/I, hook the top of the device over the lip of the DIN rail and push the device in the direction of arrow 1 (shown in Figure 3-16) until a snapping sound indicates the
connector is engaged. To remove the F/I from the rail, insert a screwdriver into the silver slot on the bottom of the device, near the DIN rail. Tip the device in the direction of arrow 2 and pull it off of the rail.
Figure 3-16: F/I – side view
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If replacing an existing F/I, the terminal strips can be disconnected from the body of the device and then reattached to the replacement part. This allows the user to replace the F/I without having to disconnect and reconnect each lead in
the cables. To disconnect a terminal strip, insert a small screwdriver in the notch shown in figure below, and pry the terminal strip out.
Figure 3-17: F/I Terminal Connections
See the Phoenix frequency converter equipment manual included with your equipment for the proper termination of cables at the F/I. Insert the leads of the cables in the terminals shown in Figure 3-17 and secure by tightening the screw
with a small flat-head screwdriver. The F/I comes pre-programmed for the bell speed control system.
Figure 3-18: F/I Faceplate
3.2.4 Turbine
Install the turbine (EO-4526-021-000) by lining up the turbine dowels with the elbow manifold dowel holes and the turbine mirror window with the elbow manifold fiber-optic line. Then slide the turbine into the elbow manifold. Refer
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to the Versabell II+ Applicator Poster (ET-5093-PST-003) for additional information on the turbine.
Figure 3-19: Turbine Dowels and Mirror Window
Figure 3-20: Elbow Manifold dowel holes and fiber-optic line
3.2.5 Fiber Optic Cable

The Fiber Optic Cable between the O/E and the indicator wheel on the turbine is split into three sections, between the PCE and the FRP, between the FRP and the Wrist QD, and inside of the Elbow Manifold.
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Figure 3-21: Fiber Optic connection points
• Refer to robot manual for the specific process equipment manual for information on the section that attaches to the O/E.
• Refer to robot manual for specific applicator hose bundle for information on the section that connects the Applicator to the terminal in the FRP.
• Refer to the Versabell II+ Applicator Poster (ET-5093-PST-003) for information on the section that passes through the Applicator to the Turbine.
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3.2.6 Software Setup

The bell speeds that are used while processing a job are commanded by entering the requested values as entries in System Color Preset table data. Bell speed commands during color change are entered as parameters in Color Change
Presets. The PaintTool software application in the robot control system sends these commands to the Bell Speed Control System.
Setting Cruise Speed

The cruise speed is the commanded bell speed when the robot is not processing a job or is idle. Use the STARTUP Bell Speed test in the Setup Menu to set the cruise speed, shown in figure 3-22. Use SPEED+ and SPEED- to set the
desired cruise speed. Typically the cruise speed is set to 30krpm.
Figure 3-22: STARTUP Bell Speed screen
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3.3 Troubleshooting
This section provides troubleshooting guidelines for faults generated by the Bell Speed Control System. This section is organized by PaintTool fault number (note that PNT1 faults are documented here, but PNT2 faults with the same
fault name would have the same troubleshooting procedure.). Eq1 faults reference robot equipment 1 and Eq2 faults reference robot equipment 2 for each controller. Each bell speed fault has its PaintTool manual description and remedy.
The most common faults are then followed by a “Troubleshooting procedure” which offers instruction on steps to take to isolate the malfunction.
3.3.1 Eq1: PNT1-701 PAUS %sMax. output has speed < setpoint
Cause: With a maximum control output the speed was measured to be lower than the setpoint (requested speed). This can occur if:
1. Paint has backed up into the turbine.
2. The turbine air line is pinched.
3. The turbine air pressure is too low.
Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine air supply pressure. Check and replace the I/P transducer, if necessary.
Troubleshooting procedure:
1. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
2. Verify bearing air is turned on.
3. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.
4. If spindle won’t turn easily by hand then replace turbine.
5. If spindle turns, then
a. Replace turbine with a part that is known to be good.
b. Command replacement turbine at speeds up to set point. If each speed is met with no alarms, then replace turbine.
c. If PNT1-701 alarm reoccurs, then check turbine air lines for kink or other issues.
d. If no issues with hose, perform Keyence optical feedback test from section 3.4.1.
1. Spin the turbine by hand and look at the display value on the O/E unit
2. If the maximum display value is less than 2000 then perform Bell speed feedback troubleshooting in section 3.4.2.
3. If the maximum display value is 2000 or greater, then replace I/P Transducer (in PCE).The original turbine may be returned to the applicator.
3.3.2 Eq1: PNT1-702 WARN %sRequested speed over valid range
Cause: The requested turbine speed output command is above the range that is considered valid. Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.
Remedy: N/A
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3.3.3 Eq1: PNT1-703 WARN %sFailed to reach setpoint
Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of Min. set point reached (ms) value. This can be caused by attenuation in the bell speed fiber optic lines, low air supply pressure or other
failures. This may occur with the alarm Max. output has speed < setpoint . If the Max. output has speed < setpoint alarm is also in the alarm log follow the remedies for that alarm. Examine the displayed turbine speed and evaluate if it is
bouncing a lot. If so increase the Tolerance Band parameter between 30% to 50% of its original value.
Remedy: N/A
3. Check bell speed setup parameters:
1. On teach pendant, choose SETUP menu for BELL SPEED
2. The SET POINT REACHED TOLERANCE (%) value is near the bottom of the list. The default is 3%. If the actual value is less than 3%, change the value to 3% and re-test bell speed.
4. IF PNT1-703 alarm reoccurs then continue troubleshooting.
5. Verify bearing air is turned on then check turbine. If spindle won’t turn easily by hand then replace turbine.
6. If spindle turns, then check bell speed fiber optic circuit as follows:
1. Perform Keyence optical feedback test and Bell speed feedback troubleshooting (if necessary) in section 3.4.2.
2. If both maximum values are greater than 2000, then
• Run a ghost job and collect bell speed DMON data, and contact FRA Service for further analysis.
• Replace the turbine
3.3.4 Eq1: PNT1-704 PAUS %sZero turbine speed timeout
Cause: All of the conditions were set for the turbine to be spinning but a zero speed was measured for a set time period. This might be due to no turbine air pressure. One of the following items might be broken: I/P transducer, Fiber
Optic lines, or Fiber Optic Speed OH (EE-4560-653-001) at the turbine end of the elbow manifold fiber optic line segment. The Zero Speed Timeout might be set too short.
Remedy: If the turbine can be seen spinning, check the following: Fiber Optic lines, or Fiber Optic Speed OH (EE-4560-653-001) at the turbine end of the elbow manifold fiber optic line segment. Otherwise, check all items listed in
Cause. Possibly increase the Zero Speed Timeout by about 50% of its original value.
1. Observe the bell. If it is spinning during the alarm then:
a. Check bell speed setup parameters:
• On teach pendant, choose SETUP menu for BELL SPEED
• The ZERO SPEED TIMEOUT (ms) value is near the bottom of the list. The default is 3000 (3000 ms = 3 seconds). If the actual value is less than 3000, change the value to 3000 and re-test bell speed.
2. If PNT1-704 re-occurs then there is a feedback issue
• Perform the Keyence optical feedback test.
• Perform the Bell speed feedback troubleshooting procedure.
3. If the bell is not spinning
a. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
b. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.
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5. If spindle turns, then verify connections to turbine drive I/P transducer (in PCE):
a. Verify electrical cable is connected properly.
b. Verify air connections are plumbed properly.
6. If no issues are found with the connections of the I/P transducer, then replace the I/P transducer.
3.3.5 Eq1: PNT1-705 PAUS %sTurbine over speed
Cause: While the turbine was operating the RPM level was above the Over speed limit. When this error occurs, a fault is posted by the controller and the robot and applicator are stopped.
Remedy: N/A
a. On teach pendant, choose SETUP menu for BELL SPEED
b. The MAXIMUM SPEED (krpm) default value is 65. If the actual value is less than 65, change the value to 65 and re-test bell speed.
2. If the fault continues with MAXIMUM SPEED set to 65, then reset the I/P transducer:
a. Put the controller in TEACH Mode.
b. Cycle power on the controller.
3. If the fault continues to occur then perform the Keyence optical feedback test in section 3.4.1.
a. If the maximum display value from the Keyence optical feedback test is less than 2000, then perform the Bell speed feedback troubleshooting procedure in section 3.4.2..
b. If the maximum display value is above 2000, then replace the turbine drive I/P transducer.
3.3.6 Eq1: PNT1-706 PAUS %sTurbine under speed fault
Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the Manual Under speed limit. Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one is
low, increase it. Possibly decrease the Manual Under speed limit value.
Remedy: N/A
b. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
c. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
d. Correct the parameter values.
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3.3.7 Eq1: PNT1-707 WARN %sTurbine under speed warning
Cause: While the gun was off or disabled and the turbine was operating the RPM level was below the Manual Under speed limit. Check and replace the I/P transducer if necessary. Check the supply air pressures,. If it is low, increase to
85 to 87psi. Possibly decrease the Manual Under speed limit value.
Remedy: N/A
3.3.8 Eq1: PNT1-708 WARN %sSpeed avg. error excessive
Cause: Checks for how far the speed is from the set point. Possible causes are:
• A sticking I/P transducer
• Low supply air pressure
Remedy: Check and replace the I/P transducer if necessary. Check the supply air pressures, If it is low, increase to 85 to 87psi. Possibly decrease the Max. error from setpoint parameter.
3.3.9 Eq1: PNT1-709 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bearing Air is above the minimum pressure is not ON. Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.
Remedy: N/A
Troubleshooting
1. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct. If pressure is correct then continue troubleshooting.
2. Use a gage that is known to be good and verify the pressure reading of the bearing air sensor. Replace the bearing air sensor if its reading is incorrect.
3.3.10 Eq1: PNT1-710 WARN %sCruise Speed not established
Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.
Remedy: Redo the Bell Speed Startup Test in section 3.2.6 to set a new Cruise Speed, or check the turbine or turbine drive I/P.
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3.3.11 Eq1:PNT1-716 WARN %sTurbine Startup Test Not Complete
Cause: The Bell Speed Control Startup Test for the turbine is not complete. This test must be performed before running the turbine.
Remedy: Check the Start Mode field on the Bell Speed SETUP menu to check the status of the Startup Test. If it has not been performed, run the Bell Speed Control Startup Test from section 3.2.6.
3.3.12 Eq1: PNT1-717 PAUS %sMax.dV/dT detected
Cause: A velocity change within a measured time has exceeded the maximum dV/dT setting for this turbine.
Remedy: Check the Keyence unit inside of the robot PCE to determine if the feedback signal from the turbine is consistent.
3.3.13 Eq2: PNT1-718 PAUS %sMax. output has speed < setpoint
Cause: With a maximum control output the speed was measured to be lower than the setpoint (requested speed). This can occur if:
1. Paint has backed up into the turbine.
2. The turbine air line is pinched.
3. The turbine air pressure is too low.
Remedy: Check the turbine lines for pinching, especially at places where they flex. Check the turbine air supply pressure. Check and replace the I/P transducer, if necessary.
2. Verify bearing air is turned on.
4. If spindle won’t turn easily by hand then replace turbine.
5. If spindle turns, then
e. Replace turbine with a part that is known to be good.
f. Command replacement turbine at speeds up to set point. If each speed is met with no alarms, then replace turbine.
g. If PNT1-701 alarm reoccurs, then check turbine air lines for kink or other issues.
h. If no issues with hose, perform Keyence optical feedback test from section 3.4.1.
1. Spin the turbine by hand and look at the display value on the O/E unit
2. If the maximum display value is less than 2000 then perform Bell speed feedback troubleshooting in section 3.4.2.
3. If the maximum display value is 2000 or greater, then replace I/P Transducer (in PCE).The original turbine may be returned to the applicator.
3.3.14 Eq2: PNT1-719 WARN %sRequested speed over valid range
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Cause: The requested turbine speed output command is above the range that is considered valid. Adjust the turbine speed command that is used in the preset table so it is within an acceptable range.
Remedy: N/A
3.3.15 Eq2: PNT1-720 WARN %sFailed to reach setpoint
Cause: The turbine speed failed to come within the Tolerance Band setting within the time setting of Min. set point reached (ms) value. This can be caused by attenuation in the bell speed fiber optic lines, low air supply pressure or other
failures. This may occur with the alarm Max. output has speed < setpoint . If the Max. output has speed < setpoint alarm is also in the alarm log follow the remedies for that alarm. Examine the displayed turbine speed and evaluate if it is
bouncing a lot. If so increase the Tolerance Band parameter between 30% to 50% of its original value.
Remedy: N/A
3. On teach pendant, choose SETUP menu for BELL SPEED
4. The SET POINT REACHED TOLERANCE (%) value is near the bottom of the list. The default is 3%. If the actual value is less than 3%, change the value to 3% and re-test bell speed.
4. IF PNT1-703 alarm reoccurs then continue troubleshooting.
6. If spindle turns, then check bell speed fiber optic circuit as follows:
5. Perform Keyence optical feedback test and Bell speed feedback troubleshooting (if necessary) in section 3.4.2.
6. If both maximum display values are greater than 2000, then
• Run a ghost job and collect bell speed DMON data, and contact FRA Service for further analysis.
• Replace the turbine
3.3.16 Eq2: PNT1-721 PAUS %sZero turbine speed timeout
Cause: All of the conditions were set for the turbine to be spinning but a zero speed was measured for a set time period. This might be due to no turbine air pressure. One of the following items might be broken: I/P transducer, Fiber
Optic lines, or Fiber Optic Speed OH (EE-4560-653-001) at the turbine end of the elbow manifold fiber optic line segment. The Zero Speed Timeout might be set too short.
Remedy: If the turbine can be seen spinning, check the following: Fiber Optic lines, or Fiber Optic Speed OH (EE-4560-653-001) at the turbine end of the elbow manifold fiber optic line segment. Otherwise, check all items listed in
Cause. Possibly increase the Zero Speed Timeout by about 50% of its original value.
1. Observe the bell. If it is spinning during the alarm then:
b. Check bell speed setup parameters:
• On teach pendant, choose SETUP menu for BELL SPEED
• The ZERO SPEED TIMEOUT (ms) value is near the bottom of the list. The default is 3000 (3000 ms = 3 seconds). If the actual value is less than 3000, change the value to 3000 and re-test bell speed.
2. If PNT1-704 re-occurs then there is a feedback issue
• Perform the Keyence optical feedback test.
• Perform the Bell speed feedback troubleshooting procedure.
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3. If the bell is not spinning

c. Verify process air supply pressure is 85 to 87 psi (5.8 to 6.0 Bar). If pressure is out of range, correct and test turbine. If pressure is in range then continue troubleshooting.
d. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct and test turbine. If pressure is correct then continue troubleshooting.
3.3.17 Eq2: PNT1-722 PAUS %sTurbine over speed
Cause: While the turbine was operating the RPM level was above the Over speed limit. When this error occurs, a fault is posted by the controller and the robot and applicator are stopped.
Remedy: N/A
c. On teach pendant, choose SETUP menu for BELL SPEED
d. The MAXIMUM SPEED (krpm) default value is 65. If the actual value is less than 65, change the value to 65 and re-test bell speed.
2. If the fault continues with MAXIMUM SPEED set to 65, then reset the I/P transducer:
c. Put the controller in TEACH Mode.
d. Cycle power on the controller.
3. If the fault continues to occur then perform the Keyence optical feedback test in section 3.4.1.
a. If the maximum display value from the Keyence optical feedback test is less than 2000, then perform the Bell speed feedback troubleshooting procedure in section 3.4.2..
b. If the maximum value is above 2000, then replace the turbine drive I/P transducer.
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3.3.18 Eq2: PNT1-723 PAUS %sTurbine under speed fault
Cause: While the turbine was operating and the gun was on or enabled, the RPM level was below the Manua Under speed limit. Check and replace the I/P transducer if necessary. Check the supply and pilot air pressures, if either one is
low, increase it. Possibly decrease the Manual Under speed limit value.
Remedy: N/A
e. On teach pendant, choose SETUP menu for BELL SPEED
f. The AUTO UNDER SPEED LIMIT (krpm) should be set to 0.
g. The MANUAL UNDER SPEED LIMIT (krpm) should be set to 0.
h. Correct the parameter values.
3.3.19 Eq2: PNT1-724 WARN %sTurbine under speed warning
Cause: While the gun was off or disabled and the turbine was operating the RPM level was below the Manual Under speed limit. Check and replace the I/P transducer if necessary. Check the supply air pressures,. If it is low, increase to
85 to 87psi. Possibly decrease the Manual Under speed limit value.
Remedy: N/A
3.3.20 Eq2: PNT1-725 WARN %sSpeed avg. error excessive
Cause: Checks for how far the speed is from the set point. Possible causes are:
• A sticking I/P transducer
• Low supply air pressure
Remedy: Check and replace the I/P transducer if necessary. Check the supply air pressures,. If it is low, increase to 85 to 87psi. Possibly decrease the Max. error from setpoint parameter.
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3.3.21 Eq2: PNT1-726 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bearing Air is above the minimum pressure is not ON. Check the supply pressure to the Bearing Air or verify the digital input signal is working correctly.
Remedy: N/A
Troubleshooting
1. Verify bearing air supply pressure is at least 75 psi (5.1 bar). If pressure is below 75 psi, correct. If pressure is correct then continue troubleshooting.
2. Use a gage that is known to be good and verify the pressure reading of the bearing air sensor. Replace the bearing air sensor if its reading is incorrect.
3.3.22 Eq2: PNT1-727 WARN %sCruise Speed not established

Cause: The Cruise Speed determined during the Bell Speed Startup Test could not be established.
Remedy: Redo the Bell Speed Startup Test in section 3.2.6 to set a new Cruise Speed, or check the turbine or turbine drive I/P.
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3.4 Troubleshooting Procedure

3.4.1 Keyence optical feedback test:
This test will evaluate the strength of the optical signal used to control the bell speed. The Keyence fiber optic sensor sends and receives an optical signal that is reflected off a spinning surface in the applicator turbine. The strength of the
reflected signal is displayed in a digital readout on the fiber optic sensor. The maximum value is 4095. At FANUC Robotics, systems are verified to read between 3850 and 4095 under ideal conditions. When values of the signal
reflected from the mirror are below 2000, the fiber optic system should be repaired.
1. The Keyence fiber optic sensor is visible via the through window in the PCE cover. If there is no through window, remove PCE cover.
2. The Keyence fiber optic unit displays two numbers. The green number is the signal threshold (factory setting = 1400) and the red number is the signal value.
3. While slowly turning the bell cup by hand observe the signal value (red number on the Fiber-optic sensor).
4. As bell is turned one full rotation, the signal value should rise and fall twice. Record the two maximum values (they should occur about 180 degrees apart).
5. If either maximum value is 2000 or less then perform the Bell speed feedback troubleshooting procedure.
3.4.2 Bell speed feedback troubleshooting procedure.

Use this procedure when Keyence optical feedback test produces maximum feedback values less than 2000. When bell speed feedback is weak, there are three components which may be the cause of the feedback losses: the fiber optic
wrist cable, the applicator fiber optic cable and the turbine. This procedure may help identify which of these components is causing the problem.
1. Remove applicator and perform inspections of bell speed feedback system.

• Check that light is being transmitted to the turbine end of the fiber optic line inside of the elbow manifold
• Check that all fiber optic connection points are secure
• Check that the fiber optic line is securely connected to the Keyence O/E unit.
• Check the turbine both ends of the fiber optic line inside of the elbow manifold are not damaged.
2. Remove turbine and verify all 3 o-rings on back face of turbine are installed correctly.
3. Inspect mirror (silver region) of speed wheel. This is visible through the hole adjacent to an alignment pin (near the turbine exhaust). Gently turn spindle to observe speed wheel. If mirror dirty, clean it (through the hole) with
alcohol and a lint-free cloth. IMPORTANT!: Do not disassemble turbine. Re-assembly without the proper tools can damage the turbine.
Speed “mirror” is visible through

this hole
Figure 3-23: Turbine speed wheel mirror location
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4. Inspect turbine end of applicator fiber optic cable. If fiber ends appear damaged or scratched, replace the applicator fiber optic cable. Clean the fiber ends with a soft cloth if necessary. Use only water or alcohol to clean the
fiber (other solvents will damage the fiber).
Figure 3-24: Elbow Manifold fiber-optic cable
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5. Inspect the quick disconnect end of the applicator fiber optic cable. If fiber optic ends appear damaged or scratched replace the applicator fiber optic cable. Clean the fiber ends with a soft cloth if necessary. Use only water or
alcohol to clean the fiber (other solvents will damage the fiber).
Figure 3-25: Applicator fiber-optic cable nose location
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5.
Figure 3-26: Applicator fiber-optic rear location
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6. Inspect the quick disconnect end of the wrist fiber optic cable. If fiber optic ends appear damaged or scratched replace the wrist fiber optic cable (see EG-00439 or EB-03658 below for proper procedure). Clean the fiber ends with
a soft cloth if necessary. Use only water or alcohol to clean the fiber (other solvents will damage the fiber.
1. If changes were made based on the above inspections, re-assemble the applicator and repeat Keyence optical feedback test. If both maximum feedback numbers are below 2000, or if no changes were made, continue
troubleshooting.
2. Inspect connection of wrist fiber optic cable at connector at the FRP. Verify that the connectors are retained by the plastic clips by pulling gently on the connectors. If the connection was loose, correct it and repeat the
Keyence optical feedback test.
3. If none of these inspections reveal a clear problem, then replace the components in this order (repeat the Keyence optical feedback test in section 3.4.1 after each replacement to observe the impact of the new
component).
a. Fiber optic wrist cable
b. Turbine
c. Applicator fiber optic cable
d. Inner Arm fiber optic cable
e. Keyence O/E unit
Wrist Fiber Optic Cable
Figure 3-27: Wrist Fiber-Optic Cable location
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<>Fiber EG
3.5 Spare Parts & Tools

3.5.1 Spare Parts Required
Bell Speed Fiber Optic Cable Current
Assembly Rev. Location Robot Model / Version
EE-4560-651-001 E Servo Bell Applicator N/A / N/A
EE-4560-652-002 F Servo Bell Applicator N/A / N/A
EE-4526-653-001 E VersaBell I Applicator N/A / N/A
VersaBell II Applicator (90

EE-4560-653-001 F deg) N/A / N/A
VersaBell II Applicator (60
EE-4560-653-002 C deg) N/A / N/A
EE-4560-654-001 H Outer Arm - FRP to QD P-500 / 1k (Short Arm)

P-500 / WB (Short
EE-4560-654-002 E Outer Arm - FRP to QD Arm)
P-700 / All Versions
EE-4560-654-003 E Outer Arm - FRP to QD P-500 / 1k (Long Arm)
P-500 / WB (Long
EE-4560-654-004 E Outer Arm - FRP to QD Arm)
EE-4560-654-005 E Outer Arm - FRP to QD NOT USED
EE-4560-654-006 D Outer Arm - FRP to QD P-250 / 1k (Short Arm)
EE-4560-654-007 D Outer Arm - FRP to QD P-250 / 1k (Long Arm)
EE-4560-655-001 E Inner Arm - PCE - FRP P-500 / N/A

EE-4560-655-002 A Inner Arm - PCE - FRP P-700 / N/A
Turbine
Servobell / Versabell I /
EO-4526-021-000 Versabell II / Versabell II+ P-500 (all) / P-700 (all)
A Applicator / P-250 (all)
Table 3-1: Spare parts required
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Keyence O/E Converter Assemblies Current Rev. Robot Model / Version

EE-4696-020 B P-500 / P-700iA with CPX process I/O package
EE-4696-021 A P-500iA / P-700iA / P-250iB with EX600 process I/O package
EE-4696-022 B P-700iA / P-250iB with EG / EX600 process I/O package
EE-4696-023 A P-250iA with Remote PCE
Frequency F/I Converter Assembly
EE-4696-010 A P-500 / P-700iA with CPX process I/O package
Table 3-2: Keyence O/E assemblies
3.5.2 Tools Required
No special tools are required for servicing the bell speed control system other than the tools specified for servicing the VersaBell, Versabell II, VersaBell II+ applicator.
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MARMCP7AP07071E REV. C 4 Bearing Air control
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4 Bearing Air control MARMCP7AP07071E REV. C
4 BEARING AIR CONTROL

4.1 Overview
4.1.1 Introduction
The bearing air supply and monitoring system supplies air to the turbine bearing and verifies that the pressure stays above 75 psi. The bearing air of the turbine keeps the turbine rotor (shaft) floating so that the turbine rotor is allowed to
rotate freely and not come into contact with the turbine housing.
The bearing air must always be on when the turbine is spinning. If the turbine is commanded to rotate when the bearing air is off, the turbine shaft will come into contact with the turbine housing while rotating and damage the turbine.
All air delivered to the turbine must be filtered using a 5 micron filter and have a dew point of -40°C to prevent damage to the bearing surfaces.
Figure 4-1: Bearing Air Schematic
4.2 Operations and Setup

The bearing air circuit starts at the supply panel manual regulator. The manual regulator at the supply panel connects to 2 accumulator tanks. The outlet of the accumulator tanks connects to a 8mm push to lock fitting. A dedicated 6 x 8
mm nylon hose runs from the supply panel, through the cattrac, to the PCE. Inside the PCE, the 8mm line plugs into a fitting a Y-fitting that also connects to the Bearing Air P/I Pressure Sensor. The Y-fitting outlet is 6mm. The bearing
air is then supplied through a 4 x 6 mm nylon hose to the applicator wrist manifold, where it connects to a 6mm barrel fitting. The identifying mark on the FRP plate and the quick disconnect manifold is BEAR.
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4.2.1 Manual regulator at supply panel

The manual regulator located at the supply panel regulates the flow of the air supplied to the robots connected to each pneumatic panel. The pressure setting for this regulator is 6 bar measured dynamically, i.e. when the robots are
spraying material.
Figure 4-2: Manual supply pressure regulator on the Pneumatic Supply Panel
4.2.2 Accumulator Tanks
Figure 4-3: Accumulator tank location on the Pneumatic Supply Panel
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4 Bearing Air control MARMCP7AP07071E REV. C
4.2.3 Bearing Air P/I

The Bearing Air P/I reads the pressure of the Bearing Air line inside the PCE, and sends the analog feedback value to the control system via the BEAR cable. Refer to Figures 3-4, 3-5, 3-7, and 3-8 for locations of the bearing air P/I locations.

There is no preventative maintenance for this system.
4.4 Troubleshooting
4.4.1 PNT1-709 PAUS %sBearing Air NOT OK
Cause: The digital input signal indicating the Bearing Air is above the minimum pressure is not ON.
Remedy:
• If the Bearing Air pressure is below the specified value, verify that the pressure sensor at the Pneumatic Air Supply panel is at least 85psi dynamic. If not, use the manual regulator located at the Pneumatic Air Supply panel to
increase the pressure to the correct level
• If the Pneumatic Air Supply panel pressure is at the correct level, check the Bearing Air line for any leaks. If necessary, change any fittings or lines that have leaks.
• If there are no leaks and the Bearing Air low pressure is not a problem for all robots in the zone, switch applicators with another robot that has a verified Bearing Air pressure value higher than the threshold.
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5 Shape Air Control System - D/Q MARMCP7AP07071E REV. C
5 SHAPE AIR CONTROL SYSTEM - D/Q

5.1 Overview
5.1.1 Introduction
The Shape Air Control System delivers the requested shape air flow rate to the applicator using a mechanical closed loop device to compensate for downstream pressure fluctuations and the Shape Air Sense (SAS) feedback to monitor
the system for leaks or plugged shape air nozzles. The Shape Air Sense feedback watches the manifold pressure at the Shape Air Nozzle and compares the measured value to the expected value. If the measured value falls outside the
allowed range, a warning or fault is posted to alert the user of a problem in the shape air system.
The flow control system is calibrated during assembly and does not need to be recalibrated in the field. A simple automatic procedure is used to calibrate the Shape Air Sense monitoring for the particular shape air nozzle or applicator
that is installed.

The schematic below shows the components of the Shape Air Control System and how they are connected to each other.
Figure 5-1: D/Q Shape Air Schematic
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MARMCP7AP07071E REV. C 5 Shape Air Control System - D/Q

The following sections describe the installation of the components of the Shape Air Control System and the software setup features that are required for operation.
5.2.1 D/Q Air Flow Control Valve

The D/Q Air Flow Control Valve (Digital to Flow) (EO-4696-110-008 or EO-4696-110-011) controls the shaping air flow rate in the Shape Air Control System. It receives the commanded flow rate from the Pneumatic Control System
via the communication system. Internal valves are opened or closed to deliver the requested shaping air flow rate. A mechanical closed loop flow control device continuously makes fine adjustments to compensate for down stream
pressure fluctuations.
Installation
The D/Q valve is connected to the Pneumatic Control System by a 9-pin communication cable shown that connects to the communication connection point shown in Figure 5-2. The communication cable connects to the top of the D/Q
Valve and is secured with small screws retained by the cable connector. It may be necessary to connect the cable and tighten the screws before mounting the D/Q Valve in the robot.
Figure 5-2: Communication connection point
The D/Q valve is mounted to the robot with two 6 mm socket head screws through the body of the valve shown in Figure 5-3.
The air inlet and Shape Air outlet ports on the bottom of the DQ valve shown in Figure 5-3 are 3/8 G thread. The exhaust port on the side of the D/Q valve is a 1/4 G thread. Pipe dope or Teflon tape should not be applied to the threads
of the fittings. Tighten the fittings until the seal of the G fitting is tight against the body of the DQ Valve.
The D/Q Valve air supply must be dry, filtered, and regulated to 85 psig (air quality per DIN ISO 8573-1: 3.4.4). Depending on air usage, the system pressure regulator may need to be set to 87-89 psig in order to maintain 85 psig at the
D/Q Valve inlet. Inconsistent supply pressure to the D/Q Valve will cause errors in the shape air flow regulation.
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Figure 5-3: D/Q valve block (EO-4696-110-008 & EO-4696-110-011)
5.2.2 P/I (analog output pressure gage)

The P/I (SENSO000000451O) is the pressure sensor in the Shape Air Sense system. The sensor reads the manifold pressure from the Shape Air Sense (SAS) line and sends the analog feedback value to the control system via the
communication cable marked “SAS”.
Installation
The P/I is mounted to a DIN rail by a spring-loaded clip. A push-lock fitting receives the 4mm air line (SAS). The electrical cable is connected at the top of the sensor. The sensor is set to the proper units during assembly and does not
need to be adjusted in the field. There is no setup procedure required when replacing a P/I pressure sensor (SENSO000000451O).
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Figure 5-4: Pressure Sensor (P/I) (SENSO000000451O)

Shaping air flow rates that are used while processing a job are commanded by entering the requested values as entries in System Color Preset table data. Shaping air flow rate commands during color change are entered as parameters in
Color Change Presets. The PaintTool software application in the robot control system sends these commands to the Shape Air Control System.
5.2.3.1 D/Q Air Control Valve Calibration

U
D/Q Valve calibration is only necessary if the D/Q valve is replaced or if the calibration table stored the controller memory is lost. Note: You must have the proper security level to change the D/Q calibration. A calibration table is
supplied with each D/Q Valve and is associated to the D/Q Valve by serial number. An example of the calibration table values is shown in Figure 5-5.
Warning: D/Q Valve Calibration requires that the D/Q Valve supply pressure is 85 psig. If the supply pressure is greater or less than 85 psig, the actual flow rate will be higher or lower than expected.
To edit the calibration table for D/Q valve, enter the ‘DQ Shaping Air Calibration’ screen in Paint Works.
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Figure 5-5: D/Q Valve Calibration Screen in PaintWorks
To calibrate the Shape Air Nozzle:

• Choose 10 data points of Command Value and Flow (SLPM) from the calibration table.
• Choose points that represent the full range of flow rates (for example: 25, 50, 75, 100, 125, 150, 175, 200, 225, & 250 Command Values).
• Enter these data points in the Shape Air Transducer Command column on the Shape Calibration Screen.
• After updating the D/Q Valve Calibration you should perform Shape Air Sense Calibration (see section 5.2.3.2).
5.2.3.2 Shape Air Sense Calibration

In order to provide maximum sensitivity, the Shape Air Sense feature must be calibrated whenever the Shape Air Nozzle or Applicator is changed.
Warning: Only calibrate the Shape Air Sense feature on newly cleaned Shape Air Nozzles! Calibrating using a dirty Shape Air Nozzle will reduce the sensitivity of Shape Air Sense and may result in nuisance alarms.
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To calibrate the Shape Air Sense feature:

• Select the calibrate button on the Shaping Air Calibration screen.
• Select the robot(s) to calibrate and select the Auto Calibrate button. It takes about two minutes for the calibration to finish.
• The expected pressure for each flow value is saved in the calibration table. These values are used to set warning and fault limits for the Shape Air Sense feature.
Figure 5-6: Shape Air Sense Calibration Screen in PaintWorks

Shape Air Startup Test
After the D/Q Valve and Shape Air Sense have been calibrated, a startup test can be performed on the Shape Air Control System in order to verify that it is working properly. To perform this test:
• Verify that the robot is in Manual Mode and at its home position.
• Verify that the applicator is enabled.
• Open the Fluid Maintenance Screen in Paint Works.
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Figure 5-7: Fluid Maintenance Screen in PaintWorks.
• Select the robot to be tested.

• Enter a valid Shape Air flow rate (50-500) in the Shaping Air (SLPM) field.
• Enter a time (in seconds) for the Test Duration field
• Press the ‘Start Test’ button.
• The manifold pressure (as measured by SAS) is reported in the Actual field.
• The system is working properly if this value matches the Expected Manifold Pressure within the tolerance.
5.2.3.3 Shape Air Control System Parameters

U
The following parameters can be viewed on the D/Q Calibration Screen or Shape Air Sense calibration screen in Paint Works.
D/Q Cal Status

Displays the result of the Shape Air Sense calibration for the D/Q Valve.
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Calibration Step Delay (ms)

Default: 5000
Range: 1000-9999
During calibration, the D/Q system increases the command output to the D/Q valve in even increments, waiting this length of time at each level, and records the air pressure on the output and manifold transducers. This value should be
long enough for the system to react to the command change and stabilize
Grace Period (ms)

Default: 5000
Range: 0-9999
This item is the delay time that needs to expire before the Output and Manifold pressures are monitored. The Grace period time and the Calibration step delay should be equal, allowing the D/Q system to react and stabilize before
pressures are monitored
Out of Tolerance Time (ms)

Default: 5000
Range: 0-9999
This item is the time duration that the pressure needs to be out of tolerance before a warning or an alarm is posted. This time duration starts when the grace period time ends.
Manifold Pressure Warning (%)

Default: 10
Range: 1-15
This item is the percent warning tolerance of the manifold pressure that is being monitored. If the current pressure exceeds the expected pressure by this percentage value for the duration specified by the Out Of Tolerance Time, a
warning is posted.
Manifold Pressure Alarm (%)

Default: 20
Range: 16-30
This item is the percent alarm tolerance of the manifold pressure that is being monitored. When the current pressure exceeds the expected pressure by this percentage value for the duration specified by Out of tolerance time, an alarm is
posted.

The Shape Air Control System is designed to function without planned maintenance for the life of the robot. Occasionally a failure of the supply air filter system can cause contamination the D/Q Valve and degrade its performance. The
following procedures can be used to clean the D/Q Valve of this contamination.
5.3.1 Cautions & Warnings

The following cautions and warnings should be observed every time a D/Q Valve is serviced.
Never Adjust Calibration Screws

The caps identified in Figure 5-8 cover (4) calibration screws for the D/Q Valve. There are (4) additional calibration screws under the Name Plate on the front of the valve. Adjustment of any of these screws is not necessary during the
service life of the D/Q Valve. Adjustment of these screws will result in inaccurate Shape Air flow rates, and require the unit be returned to the manufacturer for recalibration.
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Figure 5-8: Calibration Screw Covers

Never Interchange Internal Components between D/Q Valves
The piston, cylinder, and spring significantly affect the performance of the D/Q Valve. During cleaning, care should be taken to ensure that these components are reinstalled into the same valves from which they were removed.
Interchanging components between D/Q Valves may result in inaccurate Shape Air flow rates.
Replacement of Lost or Damaged Parts

Replacement parts for the D/Q Valve are available in the D/Q Valve Spare Parts Kit (EO-4696-110-031). Contact FRA Service for replacement parts. Any components that are not included in this kit (for example the piston, cylinder, or
spring) are not available as spare parts. If a component that is not part of the Spare Parts Kit is lost or damaged, the D/Q Valve must be returned to the manufacturer to be rebuilt and recalibrated.
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5.3.2 D/Q Valve Cleaning Procedure

This procedure provides instruction on the proper way to clean a D/Q Valve. This procedure can be used to clean all D/Q Valves
1. Using a 3/16” hex wrench, remove the (4) stainless steel screws in the bottom of the D/Q Valve and separate the upper valve block (aluminum) and the lower valve block (black delrin).
Figure 5-9: Upper & lower valve block orientation
2. Using a 30mm socket or wrench, remove the cap (shown in Figure 5-9), spring seat, spring, piston, and cylinder from the side of the lower valve block. If the piston and cylinder remain in the block after the cap is
removed, carefully extract them by hand.
3. Using a clean rag, wipe all oil and debris from the internal parts and blow them off with compressed air.
4. Insert the piston into the cylinder and ensure that the piston moves freely in the cylinder. This can be accomplished by gently shaking the cylinder assembly along its axis. There should be virtually no resistance to the
piston traveling the full length of the cylinder.
Figure 5-10: Evaluation of piston in cylinder
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5. Using a 5mm hex wrench, remove the Pipe Plug and Seal from the lower valve block.
Figure 5-11: Pipe Plug & Seal Removal
6. Using a 3/32” hex wrench, carefully remove the small Orifice from the lower valve block.
Figure 5-12: Orifice Removal
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7. Using a #73 drill bit in a Pin Vice, carefully clear the Orifice of any debris.
8.
Figure 5-13: Orifice Cleaning
8. Blow out the Orifice with compressed air.

9. Using a clean rag, wipe all debris and oil out of all passages in the lower valve block and all visible passages upper valve block.
10. Using compressed air, blow out all passages in the lower valve block, and all visible passages in the upper valve block.
11. Using a 3/32” hex wrench, install the Orifice in the lower valve block. Take care not to cross-thread the Orifice.
12. Using a 5mm hex wrench install the Pipe Plug and white (Teflon) Seal in the lower valve block.
13. Assemble the internal parts in the orientation shown and install the assembly in the lower valve block using a 30mm socket or wrench. Ensure that the cylinder bottoms out in the lower valve block, but do not over-
tighten the plastic threads.
Figure 5-14: Orientation of Internal Parts for Assembly

14. Align the lower valve block and the upper valve block as shown in the Figure 5-14. Reattach the upper and lower valve blocks using the (4) stainless steel screws and the 3/16” hex wrench.
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5.3.3 D/Q Valve Spare Parts Replacement Procedure

This procedure provides instruction on the replacement of D/Q Valve parts that may have been lost or damaged during cleaning (EO-4696-110-031). It is not necessary to replace all of the components at once. The parts in the kit may
be installed individually as needed.
D/Q Spare Parts Kit (EO-4696-110-031)

Components
FAC Part Number Description
EO-4696-110-032 ORIFICE
EO-4696-110-033 PIPE PLUG W/ SEAL
EO9999-200-005AU 2-018 O-RING VITON
EO9999-200-005AV 2-023 O-RING VITON
EO9999-200-005AW 2-027 O-RING VITON
EO9999-200-005AX 2-035 O-RING VITON
SEALM000000022O FESTO #354076 CUP SEAL
5.3.3.1 Replacing Lower Valve Block O-Rings

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This procedure provides instruction on the replacement of the static seal O-Rings in the lower valve block of the D/Q Valve.
1. Using a 30mm socket or wrench, remove the cap, spring seat, spring, piston, and cylinder from the side of the lower valve block. If the piston and cylinder remain in the block after the cap is removed, carefully extract them by
hand.
2. Remove existing O-Rings by pinching around the Outer Diameter in order to slip the O-Ring out of its groove as shown in Figure 5-15.
Figure 5-15: O-Rings Removal
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3. Install the proper sized O-Ring in each location as noted in Figure 5-16.
Figure 5-16: Location of O-Rings
4. Assemble the internal parts in the orientation in Figure 5-16 and install the assembly in the lower valve block using a 30mm socket or wrench. Ensure that the cylinder bottoms out in the lower valve block, but do not over-tighten
the plastic threads.
5.3.3.2 Replacing Upper Valve Block O-Rings

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This procedure provides instruction on the replacement of the static seal O-Rings in the upper valve block of the D/Q Valve.
1. Using a 3/16” hex wrench, remove the (4) stainless steel screws in the bottom of the D/Q Valve and separate the upper valve block (aluminum) and the lower valve block (black delrin).
Figure 5-17: Upper & Lower Valve Block Orientation
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Figure 5-18: Upper Valve Block O-Rings
2. Insert a small knife or pin into a tool access pocket in the O-Ring gland as shown in Figure 5-19.
3. Use the tool to pry each O-Ring out of its gland. O-Rings removed in this manner must be discarded.
Figure 5-19: O-Ring Removal
4. Install a new O-Ring of the proper size into each gland as shown in Figure 5-20.
Figure 5-20: O-Ring Installation
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5. Ensure that each O-Ring is completely seated in its gland.

6. Reassembly the Upper and Lower Valve Blocks using the 3/16” hex wrench and (4) stainless steel screws.
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5.3.3.3 Replacing the Pipe Plug and Orifice

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This procedure provides instruction on the replacement of the Pipe Plug and Orifice.
1. Using a 5mm hex wrench, remove the Orifice Plug and Seal from the lower valve block.
Figure 5-21: Removal of Pipe Plug with Seal
2. Using a 3/32” hex wrench, carefully remove the small Orifice from the lower valve block.
Figure 5-22: Orifice Removal
3. Replace the Orifice (EO-4696-110-032), Pipe Plug and Seal (EO-4696-110-033), taking care not to cross-thread any of the components.
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5.3.3.4 Replacing the D/Q Cup Seals

This procedure provides instruction on the replacement of the D/Q Cup Seals between the upper valve block and the D/Q manifold.
• Use a Phillips screw driver to remove the (4) screws retaining the cap from the D/Q manifold as shown in the Figure 5-23.
Figure 5-23: D/Q cap Removal

• Use the 3mm hex wrench to remove the (4) screws that attach the D/Q manifold to the upper valve block as shown in Figure 5-24.
Figure 5-24: D/Q Manifold Removal

• Remove and replace the D/Q cup seals (SEALM000000022O) by hand.
Figure 5-25: D/Q Cup Seals
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• Align the D/Q manifold with the upper valve block as shown in Figure 5-26 and reattach using the (4) screws and the 3mm hex wrench.
Figure 5-26: D/Q Manifold Alignment

• Secure the D/Q cap to the manifold using the (4) screws and the Phillips screw driver.
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5.3.4 Pressure Sensor (P/I)

This component requires no maintenance.
5.4 Troubleshooting
This section provides troubleshooting guidelines for faults generated by the Shape Air Control System. Possible causes and remedies are listed for each fault. The error codes listed below are of the form:
<Equipment 1 fault> / <Equipment 2 fault> “<description>
For example: PNT1-845-WARN 1 / PNT1-861 WARN 2 “Manifold Press low warning”

The two faults have the same meaning but were posted by different paint robots on this controller.
5.4.1 PNT1-845 WARN 1 / PNT1-861 WARN 2 “Manifold Press low warning”

The pressure in the shape air nozzle, which is measured by the Shape Air Sense feature, was lower than the expected value and outside the tolerance limit.
5.4.1.1 Cause: Uncalibrated Shape Air Sense

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The Shape Air Sense must be calibrated when the applicator or shape air nozzle is changed.
Remedy: Perform Shape Air Sense Calibration (section 5.2.3.2) if one of these parts was changed and the Shape Air Sense was not recalibrated.
5.4.1.2 Cause: Air Leak due to Loose Applicator

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If the applicator was not tightly connected to the quick-disconnect (QD) a leak could occur in the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS).
Remedy: Reinstall the applicator tightly on the QD.
5.4.1.3 Cause: Air Leak due to Missing O-ring in Applicator

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If one or more of the radial o-rings in the Applicator for the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) were not installed, a leak here could cause this fault.
Remedy: Remove the Applicator and reinstall the missing o-ring.
5.4.1.4 Cause: Air Leak due to Missing O-ring in Shape Air Nozzle
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If one or more of the o-rings in the Shape Air Nozzle are missing, a leak here could cause this fault. See the Versabell II+ Applicator poster in Chapter 1 for more information
Remedy: Remove the Shape Air Nozzle and reinstall the missing o-ring.
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5.4.1.5 Cause: Air Leak due to Loose line in Push-Lock Fitting

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If one of the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) is not fully inserted into a push-lock fitting, it could cause an intermittent leak.
Remedy: Check that the hoses are fully inserted at the following locations:
• Process Air Supply Manifold on outer arm. (check both sides of the manifold)
• SA1 & SA2 at the outlet of the D/Q Valve
• SAS at the P/I sensor
Reinsert loose hoses.
5.4.1.6 Cause: Air Leak due to Damaged Hose

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Damage to one of the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) could cause a leak. Inspect these lines for cracks, cuts, or pinholes.
Remedy: Replace damaged hose.
5.4.1.7 Cause: Supply Pressure Fluctuation

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Decreasing the supply pressure to the D/Q Valve will decrease the flow rate of shaping air and could cause this warning. Confirm that the air supply regulator is set correctly and is regulating to a constant pressure.
Remedy: Reset the air supply regulator to the prescribed setting (usually 85-89 psig). If 85 psig cannot be maintained at the supply regulator, investigate the air delivery system for the source of air starvation.
5.4.1.8 PNT1-846 WARN 1 / PNT1-862 WARN 2 “Manifold Press high warning”

The pressure in the shape air nozzle, which is measured by the Shape Air Sense feature, was higher than the expected value and outside the tolerance limit.

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The Shape Air Sense must be calibrated when the applicator or shape air nozzle is changed.
Remedy: Perform Shape Air Sense Calibration (section 5.2.3.2) if one of these parts was changed and the Shape Air Sense was not recalibrated.
5.4.1.10 Cause: Plugged Shape Air Nozzle Holes

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The most common cause of this warning, while processing a job, is a Shape Air Nozzle that has become dirty and has holes that are partially plugged with paint.
Remedy: Clean the Shape Air Nozzle holes as described in Section 6.2.1, or replace the Shape Air Nozzle with a clean unit and perform Shape Air Sense Calibration as shown in section 5.2.3.2.

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Increasing the supply pressure to the D/Q Valve will increase the flow rate of shaping air and could cause this warning. Confirm that the air supply regulator is set correctly and is regulating to a constant pressure.
Remedy: Reset the air supply regulator to the prescribed setting (usually 85-89 psig).
5.4.1.12 PNT1-849 PAUS 1 / PNT1-865 PAUS 2 “Manifold Press low alarm”

The pressure in the shape air nozzle, which is measured by the Shape Air Sense feature, was lower than the expected value and outside the tolerance limit.
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The Shape Air Sense must be calibrated when the applicator or shape air nozzle is changed. Perform Shape Air Sense Calibration (section 5.2.3.2) if one of these parts was changed and the Shape Air Sense was not recalibrated.
5.4.1.14 Cause: Missing Shape Air Nozzle

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If a Shape Air Nozzle was not installed in the Shroud this alarm will prevent accidental processing of a job without effective shaping air.
Remedy: Install the appropriate Shape Air Nozzle as described in the Versabell II+ Applicator poster in Chapter 1 and perform Shape Air Sense Calibration (section 5.2.3.2).

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If one or more of the radial o-rings in the Applicator for the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) were not installed, a leak here could cause this fault. See the Versabell II+ Applicator poster in Chapter 1
for more information.
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If one or more of the o-rings in the Shape Air Nozzle are missing, a leak here could cause this fault. See the Versabell II+ Applicator poster in Chapter 1 for more information.
5.4.1.18 Cause: Air Leak due to Loose line in Push-Lock Fitting

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If one of the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) is not fully inserted into a push-lock fitting, it could cause an intermittent leak. Check that the hoses are fully inserted at the following locations:
• Process Air Supply Manifold on outer arm. (check both sides of the manifold)
• SA1 & SA2 at the outlet of the D/Q Valve
• SAS at the P/I sensor
Remedy: Reinsert the loose hose.
5.4.1.19 Cause: Air Leak due to Damaged Hose

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Damage to one of the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) could cause a leak. Inspect these lines for cracks, cuts, or pinholes.
Remedy: Replace damaged hose.

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Decreasing the supply pressure to the D/Q Valve will decrease the flow rate of shaping air and could cause this alarm. Confirm that the air supply regulator is set correctly and is regulating to a constant pressure.
Remedy: Reset the air supply regulator to the prescribed setting (usually 85-89 psig). If 85 psig cannot be maintained at the supply regulator, investigate the air delivery system for the source of air starvation.
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5.4.1.21 PNT1-850 PAUS 1 / PNT1-866 PAUS 2 “Manifold Press high alarm”

The pressure in the shape air nozzle, which is measured by the Shape Air Sense feature, was higher than the expected value and outside the tolerance limit.

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The Shape Air Sense must be calibrated when the applicator or shape air nozzle is changed. Perform Shape Air Sense Calibration (section 5.2.3.2) if one of these parts was changed and the Shape Air Sense was not recalibrated.
5.4.1.23 Cause: Plugged Shape Air Nozzle Holes

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The most common cause of this alarm, while processing a job, is a Shape Air Nozzle that has become dirty and has holes that are partially plugged with paint.
Remedy: Clean the Shape Air Nozzle holes as described in Section 6.2.1, or replace the Shape Air Nozzle with a clean unit and perform Shape Air Sense Calibration as shown in section 5.2.3.2.

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Increasing the supply pressure to the D/Q Valve will increase the flow rate of shaping air and could cause this alarm. Confirm that the air supply regulator is set correctly and is regulating to a constant pressure.
Remedy: Reset the air supply regulator to the prescribed setting (usually 85-89 psig).
5.4.1.25 PNT1-851 PAUS 1 / PNT1-867 WARN 2 “Calibration successful”

Shape Air Sense calibration was successful
Remedy: None.
5.4.1.26 PNT1-852 PAUS 1 / PNT1-868 WARN 2 “Calibration aborted”

The Shape Air Sense calibration was not completed successfully.
5.4.1.27 Cause: Robot mode of operation incorrect

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Shape Air Sense calibration was aborted because the robot was not in the correct mode to perform calibration.
Remedy: The robot must be in manual mode at the home position, with process air on, and with all faults reset.
5.4.1.28 Cause: Calibration interrupted by another fault

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Another fault occurred during calibration and calibration could not be completed successfully.
Remedy: Determine what fault interrupted the calibration, correct it, and repeat the calibration procedure.
5.4.1.29 PNT1-853 PAUS 1 / PNT1-869 WARN 2 “Non-incr cal table”

Shape Air Sense calibration was aborted because the Shape Air Sense (SAS) pressure did not increase when the commanded flow rate increased.
5.4.1.30 Cause: Air supply regulator set incorrectly

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If the supply pressure regulator is set too low, the air supply pressure to the D/Q Valve will be low and the D/Q Valve will not deliver the commanded flow rate.
Remedy: Adjust supply pressure regulator to provide correct pressure.
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5.4.1.31 Cause: Loose line in Push-Lock Fitting

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If one of the supply lines is not fully inserted into a push-lock fitting, the leak will reduce the pressure of the air supplied to the D/Q Valve.
Remedy: Check the following locations for loose tubes in the push-lock fittings.
• DQ1 & DQ2 at D/Q Valve
• DQ1 & DQ2 at the air supply manifold in the robot carriage
• Air lines on top of the rail, in the rail, or in the cross beams. Note: leaks at these locations will also affect other devices that rely on process air (turbine, Pneumatic Control System, etc…)
Reconnect any tubes that are found to be loose.
5.4.1.32 Cause: Damaged Hose

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Damage to one of the supply lines could cause a leak.
Remedy: Inspect these lines for cracks, cuts, or pinholes.

• DQ1 & DQ2 between D/Q Valve and air supply manifold
• Process air supply. Note: leaks at these locations will also affect other devices that rely on process air (turbine, Pneumatic Control System, etc…)
Replace damaged hoses.
5.4.1.33 PNT1-854 PAUS 1 / PNT1-870 WARN 2 “Zero Pressure”

Shape Air Sense calibration was aborted because the Shape Air Sense (SAS) pressure measured zero psig after the flow command was issued.
5.4.1.34 Cause: Air supply regulator set incorrectly

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If the supply pressure regulator is set too low, the D/Q Valve will not deliver the commanded flow rate.
Remedy: Adjust supply pressure regulator to provide correct pressure.

5.4.1.35 Cause: Disconnected line in Push-Lock Fitting
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If one of the supply lines is not fully inserted into a push-lock fitting, the leak will reduce the pressure of the air supplied to the D/Q Valve.
Remedy: Check the following locations for loose tubes in the push-lock fittings.
• DQ1 & DQ2 at D/Q Valve
• DQ1 & DQ2 at the air supply manifold in the robot carriage
• Air lines on top of the rail, in the rail, or in the cross beams. Note: leaks at these locations will also affect other devices that rely on process air (turbine, Pneumatic Control System, etc…)
Reconnect any tubes that are found to be loose.
5.4.1.36 Cause: Damaged Hose

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Damage to one of the supply lines (DQ1 & DQ2, or process air supply) could cause a leak.
Remedy: Inspect the following lines for cracks, cuts, or pinholes.

• DQ1 & DQ2 between D/Q Valve and Air supply manifold in carriage.
• Process air supply lines (in catrack, in rail, or in cross beams) Note: leaks at these locations will also affect other devices that rely on process air (turbine, Pneumatic Control System, etc…)
Replace damaged hose.
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5.4.1.37 Cause: Leak in Shape Air Sense line

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If the shape air sense line is disconnected, the Shaping Air Control System will report zero manifold pressure.
Remedy: Inspect the SAS line for leaks due to damage or a loose connection at the following locations:
• Process air manifold in Axis 3 housing
• SAS Pressure sensor (P/I) in process enclosure
• Barrel fitting at applicator quick disconnect
Replace damaged lines or reconnect loose hoses in push-lock fittings
5.4.1.38 Cause: Missing Shape Air Nozzle

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If a Shape Air Nozzle was not installed in the Shroud this alarm will prevent accidental processing of a job without effective shaping air.
Remedy: Install the appropriate Shape Air Nozzle and perform Shape Air Sense Calibration, described in the section above.

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If one or more of the radial o-rings in the Applicator for the shape air supply lines (SA1 & SA2) or the shape air sense line (SAS) were not installed, a leak here could cause this fault. See the Versabell II+ Applicator poster in Chapter 1
for more information.

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If one or more of the o-rings in the Shape Air Nozzle are missing, a leak here could cause this fault. See the Versabell II+ Applicator poster in Chapter 1 for more information.

The following spare parts are used to service the Shape Air Control System.
D/Q Valve Spare Parts Kit (EO-4696-110-031)

• Includes:
o (2) Orifice (EO-4696-110-032) (1 required for each D/Q Valve, 2 included for convenience)
o Pipe Plug with Seal (EO-4696-110-033)
o Viton O-Ring #2-018 (EO9999-200-005AU)
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o Viton O-Ring #2-023 (EO9999-200-005AV)

o Viton O-Ring #2-027 (EO9999-200-005AW)
o Viton O-Ring #2-030 (EO9999-200-005T)
o Viton O-Ring #2-035 (EO9999-200-005AX)
o (8) D/Q Cup Seal #354076 (SEALM000000022O)
• P/I pressure sensor has no spare parts
• See the robot manual for hose bundle spare part information.
• See the Versabell II+ Applicator poster in Chapter 1 for spare parts information.

The following tools are required to perform maintenance on the Shape Air Control System.
• 30mm socket or wrench

• 3/16” hex wrench
• 3/32” hex wrench
• 3mm hex wrench
• 5mm hex wrench
• Small Phillips Screw Driver
• Small knife or pin
• Pin Vice – Brown & Sharpe #599-790-1 (0-.040”)
• #73 (0.024”) drill bit
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MARMCP7AP07071E REV. C 6 Shape Air Control System - AccuAir
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6 Shape Air Control System - AccuAir MARMCP7AP07071E REV. C
6 SHAPE AIR CONTROL SYSTEM - ACCUAIR

6.1 Overview
6.1.1 Introduction
The Shape Air Control System delivers the requested shape air flow rate to the applicator using a closed loop control system to compensate for downstream pressure fluctuations. The pressure transducer watches the flow output from the
flow meter and adjusts the pressure accordingly so that the requested air flow is delivered to the applicator.
The flow control system is calibrated during assembly and does not need to be recalibrated in the field. A simple automatic procedure is used to update the pressure transducer calibration table for the particular shape air nozzle or
applicator that is installed.

6.1.2.1 Single Shape Air - AccuAir
Figure 6-1: Single Shape Air AccuAir Schematic
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6.1.2.2 Dual Shape Air – AccuAir
Figure 6-2: Dual Shape Air AccuAir Schematic

Note:
• Detailed information on the AccuAir Pneumatic Control System is described in this chapter
• Detailed information on the Shape Air Nozzle can be found in section 1.

6.2.1 Introduction
The AccuAir Shape Air Control System does not include any field serviceable control components. Any faulty component, such as the flow meter or pressure transducer, should be replaced with a new component.
If the shape air nozzles are contaminated, make sure that solvent is flowing through the shape air nozzles during a cleanout color change cycle. If the shape air nozzles are still contaminated, use a torch tip cleaner to physically remove
debris found inside the shape air nozzles. Torch tip cleaners available for use can be found at McMaster-Carr with part number 7646A2. Use size cleaner size 6 tip cleaner, the smallest cleaner of the set, to remove debris first. If debris
remains, use size 7 tip cleaner.

The following sections describe the installation of the components of the Shape Air Control System and the software setup features that are required for operation.
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6.3.1 EX600
EthernetIP Address Setup

<>EX600 IPaddress
6.3.2 Flow Meter

The flow meter (HPNMO000019116O) measures the shaping air flow rate in the Shape Air Control System, and sends the measured flow back to the Pneumatic Control System via the communication system.
Installation
The flow meter is connected to the Pneumatic Control System by a 4-pin communication cable that connects to the top of the flow meter. The flow meter is held in place by 4 screws included with the device. These screws can be
attached to the PCE itself, or to a bracket inside of the PCE. The Flow meter position and components are shown in Figure 6-3 for P-700/P-250 and Figure 6-4 for P-500.
Figure 6-3: Flow meter components. P-700iA PCE
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Figure 6-4: Flow meter components. P-500iA PCE
The air inlet ports and outlet ports of the flow meter are 3/8 G thread. A straight 12mm push-lock fitting is connected to each port. Pipe dope or Teflon tape should not be applied to the threads of the fittings. Tighten the fittings until the
seal of the G fitting is tight against the body of the flow meter.
The shape air supply must be dry and filtered (air quality per DIN ISO 8573-1: 3.4.4).
6.3.3 Pressure Transducer

The pressure transducer (TDUCO00000019O) regulates the pressure based on a command value from the controller or teach pendant.
Installation
The pressure transducer is mounted inside the PCE either directly to the PCE body or to a bracket that is connected to the PCE body. A push-lock fitting receives the 12mm air line from the flow meter. Another push-lock fitting
connects to the outlet of the transducer, which leads to the applicator. The electrical cable is connected at the top of the transducer.
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Figure 6-5: Pressure Transducer, P-700iA PCE
Figure 6-6: Pressure Transducer, P-500iA PCE
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Shaping air flow rates that are used while processing a job are commanded by entering the requested values as entries in System Color Preset table data. Shaping air flow rate commands during color change are entered as parameters in
Color Change Presets. The PaintTool software application in the robot control system sends these commands to the Shape Air Control System.
6.3.4.1 Shape Air Calibration

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Shape air calibration table

In order to provide maximum sensitivity, the shape air calibration table must be updated whenever the Shape Air Nozzle or Applicator is changed. To calibrate the shape air system, use the calibration procedure in PaintTool.
Warning: Only update the shape air calibration table feature on newly cleaned Shape Air Nozzles! Calibrating using a dirty Shape Air Nozzle will reduce the sensitivity of shape air flow and may result in redundant alarms.
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The Shape Air Control System is designed to function without planned maintenance for the life of the robot. Occasionally a failure of the supply air filter system can cause contamination the flow meter or pressure transducer and
degrade its performance. In this situation, replace the faulty component.
6.4 Troubleshooting
This section provides troubleshooting guidelines for faults generated by the Shape Air Control System. Possible causes and remedies are listed for each fault. The errors posted here are in the form of <Error Number><Warning or
Fault> %s <Description>, where %s is a placeholder for Shape Air 1, or optionally Shape Air 2, depending on which shape air system is being used.
6.4.1 Eq1: PNT1-616 WARN %sCalibration successful

Cause: Used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
6.4.2 Eq1: PNT1-617 WARN %sCalibration aborted

Cause: AccuAir calibration could not complete. Possible reasons for aborting the calibration are:
• The air supply being off.

• Incorrect setup parameters.
• Incomplete hardware setup.
Remedy: Check for other alarms in the log. The best remedy might be found from the previous alarm in the log. Request proper air flow through the air system, and check that it occurs. Check that the warning and fault percentages and
various other parameters are set properly. Increase the Calibration time out parameter.
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6.4.3 Eq1: PNT1-618 WARN %sCal. low flow rate reset

Cause: This is a warning not a failure. During AccuAir calibration the low flow rate could not be properly reached. A new flow rate was established. The target minimum flow rate is Point no. 2 of the calibration table in the parameter
setup screen.
Remedy: The new flow rate is shown as point 2 in the calibration table. This value can be visually checked and accepted. Increase the yield of the system by increasing air line diameters to the applicator. Point no. 2 of the calibration
table in the parameter setup menu can be increased (by about 100%).
6.4.4 Eq1: PNT1-619 WARN %sCal. max. flow rate reset

Cause: This is a warning, not a failure. During AccuAir calibration, the expected maximum flow rate could not be reached at the maximum output. A new maximum flow rate was established.
Remedy: The new maximum flow rate is shown as point 10 in the calibration table. This value can be visually checked, and accepted
6.4.5 Eq2: PNT1-647 WARN %sCalibration successful

Cause: Used to notify the cell controller that a calibration has been completed successfully.
Remedy: None.
6.4.6 Eq2: PNT1-648 WARN %sCalibration aborted

Cause: AccuAir calibration could not complete. Possible reasons for aborting the calibration are:
• The air supply being off.

• Incorrect setup parameters.
• Incomplete hardware setup.
Remedy: Check for other alarms in the log. The best remedy might be found from the previous alarm in the log. Request proper air flow through the air system, and check that it occurs. Check that the warning and fault percentages and
various other parameters are set properly. Increase the Calibration time out parameter.
6.4.7 Eq2: PNT1-649 WARN %sCal. low flow rate reset

Cause: This is a warning not a failure. During AccuAir calibration the low flow rate could not be properly reached. A new flow rate was established. The target minimum flow rate is Point no. 2 of the calibration table in the parameter
setup screen.
Remedy: The new flow rate is shown as point 2 in the calibration table. This value can be visually checked and accepted. Increase the yield of the system by increasing air line diameters to the applicator. Point no. 2 of the calibration
table in the parameter setup menu can be increased (by about 100%).
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6.4.8 Eq2: PNT1-650 WARN %sCal. max. flow rate reset

Cause: This is a warning, not a failure. During AccuAir calibration the expected maximum flow rate could not be reached at the maximum output. A new maximum flow rate was established.
Remedy: The new maximum flow rate is shown as point 10 in the calibration table. This value can be visually checked and accepted.
6.4.9 Eq1: PNT1-626 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint (requested flow). The maximum control out (ms) parameter affects the sensitivity of this alarm. This is likely caused by a dirty shape air
nozzle ring. This might also be caused by:
• Pinched air lines

• A broken I/P transducer
• A broken air flow sensor
Note: AccuAir temporarily and automatically changes to Open Loop when this alarm occurs.
Remedy: Check, clean, and possibly replace the air nozzle. If air is observed to be flowing (when commanded), possibly replace the air flowmeter. Also check the following:
• Check for a pinched air line.

• Check and repair the I/P transducer.
• Increase the Max. control out (ms) parameter (by about 50%), if possible.
6.4.10 Eq1: PNT1-632 WARN %s0 air flow rate timeout

Cause: All of the conditions were set for air to be flowing but a zero flow rate was measured for longer than the Zero flow timeout parameter. This might be caused by:
• A clogged air nozzle
• Broken air lines
• A loss of air supply pressure
• A broken cable to the flow sensor
• A Zero flow time-out value that is too short.
Remedy: Check the following:
• Check, clean, and possibly replace the air nozzle.

• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a broken air line.
• Increase the Zero flow timeout parameter by about 25%, if possible.
Increase the Zero flow time-out parameter (by about 25%), if possible.
-162-
6.4.11 Eq2: PNT1-657 WARN %sMax. output has flow < setpoint
Cause: With a maximum control output, the flow rate was measured to be lower than the setpoint (requested flow). The maximum control out (ms) parameter affects the sensitivity of this alarm. This is likely caused by a dirty shape air
nozzle ring. This might also be caused by:
• Pinched air lines

• A broken I/P transducer
Remedy: Check, clean, and possibly replace the air nozzle. If air is observed to be flowing (when commanded), possibly replace the air flowmeter. Also check the following:
• Check for a pinched air line.

• Check and repair the I/P transducer.
• Increase the Max. control out (ms) parameter (by about 50%), if possible.
6.4.12 Eq2: PNT1-663 WARN %s0 air flow rate timeout

Cause: All of the conditions were set for air to be flowing but a zero flow rate was measured for longer than the Zero flow timeout parameter. This might be caused by:
• A clogged air nozzle
• Broken air lines
• A loss of air supply pressure
• A broken cable to the flow sensor
• A Zero flow time-out value that is too short.
• Check, clean, and possibly replace the air nozzle.

• If air was observed to be flowing, check and possibly replace the air flow sensor.
• Check for a broken air line.
• Increase the Zero flow timeout parameter by about 25%, if possible.
-163-
-164-
7 Seal Air control MARMCP7AP07071E REV. C
7 SEAL AIR CONTROL

7.1 Overview
Seal air pressure is set with a manual air regulator located in the PCE on the outer arm. A 4 x 6 mm nylon hose (SEAL) connects from the regulator to the applicator wrist manifold. The purpose of Seal Air is to help maintain a clean
surface on the back of the bell cup, as well as the front face of the turbine.

The manual regulator is located in the PCE as shown in Figure 7-1. A 4 x 6 mm hose connects the manual regulator to the EX600 and another 4 x 6 mm hose connects the regulator to the Quick Disconnect manifold. The manual
regulator should be set such that the flow rate is set to 120slpm. (approximately 20 psig).
Figure 7-1: P-500iA Manual seal air regulator
Figure 7-2: P-700 Seal air manual regulator
-165-
MARMCP7AP07071E REV. C 7 Seal Air control

There is no scheduled maintenance for this item.
7.4 Troubleshooting
• If the back face of the bell cup continues to become contaminated, disassemble the applicator to the Seal Air Nozzle. Check to verify that the gap between the seal air nozzle and shape air nozzle in the applicator, as shown in Figure 7-3,
is clean and holes in the Shape Air Nozzle are clean. If either area is not clean, please clean.
Figure 7-3: Gap between seal air nozzle and shape air nozzle
• Check the seal air line for leaks.
• Verify Seal Air flow.
• If the flow rates are the same, replace manual regulator.
7.5 Spare Parts and Tools
No special tools.
No wearable parts.
-166-
7 Seal Air control MARMCP7AP07071E REV. C
-167-
MARMCP7AP07071E REV. C 8 IPC Paint delivery system
-168-
8 IPC Paint delivery system MARMCP7AP07071E REV. C
8 IPC PAINT DELIVERY SYSTEM

8.1 Overview
The FANUC Robotics Integral Pump Control (IPC) system is a precision gear pump metering system for paint. The system uses FANUC Robotics servo motors and control along with 3cc/rev and 6cc/rev gear pumps. The metering
system is integrated into the robot controller. The robot controls ratio, monitors pressures, faults, and the fluid pump. All setup and operation of the IPC system can be done from the robot Teach Pendant or the System GUI (if
configured with one). Each color in a 2K paint system can be configured with its own ratio (if required). The IPC system monitors the outlet pressure of the gear pump. The outlet sensor works in conjunction with the inlet regulator to
ensure optimal pressure differential across the pump. Optionally, the IPC system can measure the feedback flow rate through a flow meter or pump inlet pressure for finer flow control.
-169-

The procedures for installation of the IPC drive shaft, pump, pump block, pump manifold, and pump QD to the robot are shown in ET-5093-890-007 for P-700 1K pump systems, and ET-6102-890-007 for P-500 1-K pump systems.
Figure 8-1 ET-5093-890-007 Sheet 1 of 2, 1K PUMP
WARNING
Some components are heavy. Use
extreme care and follow proper lifting
procedures when you install or remove
components. Otherwise you could
injure personnel or damge equipment
WARNING
Always disconnect power to the robot
before you perform any service or
maintenance procedures. Otherwise,
you could injure personnel or damage
equipment.
UNLESS OTHERWISE NOTED:

SEE EG-00008 FOR LOCTITE REQUIREMENTS
SEE EG-00010 FOR TORQUE SPECIFICATIONS
O-RINGS ON THIS SURFACE
4X SSHCM006100020G MUST BE IN PLACE
PRIOR TO INSTALLATION
EO-5093-526-000 SCREWS SHOULD BE IN PLACE

INSTALLED IN ARM AND CAPTURED BY O-RINGS
PRIOR TO MATING PRIOR TO INSTALLATION
WITH EO-5093-521-000
4X SSHCM006100055S
TORQUE PER EG-00010 EE-4696-267-004
P/I CABLE
(9.2 N-m, 6.8 ft-lb) SEE NOTE 4
EO-5093-512-001
PUMP SHAFT RETAINER O-RINGS MUST BE IN PLACE
EO-5093-521-000
PUMP MANIFOLD ASSEMBLY
O-RINGS MUST BE IN PLACE

PUMP
EO-5093-512-002 ITEM 'A'
CUSHION SEE NOTE 2
2X SSHCM006100040G
PUMP DRIVE SHAFT
ITEM 'B'
EXPLODED ISO VIEW

SCALE 1:5
ASSEMBLY NOTES:
1. INSTALL P/I CABLE (EE-4696-267-004) INTO CORD GRIP
(CGRPO000000398O)
NOTES: 2. INSTALL PUMP QD ASM (EO5093-526-000) INTO OUTER
ARM (EO5093-020-001A)
1. UNLESS OTHERWISE SPECIFIED TORQUE ALL FASTNERS PER EG00010.
2. THE FOLLOWING STEPS SHOULD BE FOLLOWED TO INSTALL THE KEY IN 3. INSTALL CUSHION (EO-5093-512-001) INTO PUMP DRIVE
THE KEYWAY ON THE PUMP SHAFT. SHAFT (EO5093-020-012B)
a. APPLY LOCTITE PRIMER 'N' TO KEY & KEYWAY. WAIT 30 SECONDS.
b. APPLY A SMALL AMOUNT OF LOCTITE 680 TO KEYWAY ON PUMP SHAFT. 4. INSTALL PUMP DRIVE SHAFT (EO5093-020-012B) ONTO
CAUTION: PRODUCT CURES QUICKLY PUMP MOTOR OUTPUT SHAFT IN OUTER ARM (EO5093-020-
c. IMMEDIATELY INSTALL KEY IN KEYWAY. 001A)
d. IMMEDIATELY WIPE ALL EXCESS LIQUID FROM PUMP SHAFT.
3. PLUG UNUSED RETAINER MOUNTING HOLES 5. INSTALL PUMP SHAFT RETAINER (EO-5093-512-001) AS
4. SEE OUTER ARM ASSEMBLY EO5093-020-000A FOR ADDITIONAL CABLE NOTED INTO OUTER ARM (EO5093-020-001A)
ROUTING
5. CAP PILOT LINES USING CAPMO000000101O FOR STORAGE OF THIS 6. INSTALL GEAR PUMP (EO-4657-511-000) ONTO PUMP
SUBASSEMBLY MANIFOLD (EO-5093-521-000) Standard Hardware Descriptions
FANUC Part No. Description
7. INSTALL PUMP MANIFOLD (EO-5093-521-000) AND GEAR SSHCM006100020G M6 X 1.0 X 20mm LG. Glass Filled Nylon Socket Head Cap
PUMP (EO-4657-511-000) INTO OUTER ARM (EO5093-020-001A) SSHCM006100040G M6 X 1.0 X 40mm LG. Glass Filled Nylon Socket Head Cap
SSHCM006100055S M6 X 1.0 X 55mm LG. Stainless Steel Socket Head Cap
[ET-5093-890-007] REV A
1K PUMP SHEET 1 OF 2
-170-
Figure 8-2 ET-5093-890-007 Sheet 2 of 2, 1K PUMP
WARNING
GEAR PUMP PREVENTIVE MAINTENANCE

WARNING
• FLUSH PUMP WITH SOLVENT EVERY FOUR HOURS, AT BREAK AND END OF SHIFT. Always disconnect power to the robot
• REPLACE PUMP DYNAMIC SEALS ACCORDING TO THE RECOMMENDED SCHEDULE. THE PROPER before you perform any service or
PROCEDURE AND REQUIRED TOOLS ARE EXPLAINED IN EG00381. maintenance procedures. Otherwise,
WEEKLY MAINTENANCE equipment.
1. VISUALLY INSPECT THE PUMP FOR ANY LEAKS. EXAMINE PUMP INPUT SHAFT, SEAL PLATE, AND PAINT UNLESS OTHERWISE NOTED:
FITTINGS. IF ANY LEAK IS FOUND, REMOVE FROM SERVICE AND INSPECT. LEAK SERVICE MAY BE SEE EG-00008 FOR LOCTITE REQUIREMENTS
PERFORMED BY CUSTOMER PERSONNEL ACCORDING TO THE PROCEDURE IN THE MANUAL.
2. CHECK FLOWRATES OF DIFFERENT MATERIALS WITH A BEAKER. AS A GENERAL RULE, A PUMP OUTPUT SEE EG-00010 FOR TORQUE SPECIFICATIONS
VARIATION OF 10% OR MORE INDICATES A NEED TO REPLACE OR REBUILD THE PUMP. RETURN TO
FANUC ROBOTICS AMERICA.
3. LISTEN FOR ANY NOISE FROM THE PUMP WHILE IT DISPENSES PAINT. SOME NOISE IS EXPECTED DURING
SOLVENT FLUSH, BUT THE PUMP SHOULD RUN SMOOTHLY WHILE DISPENSING PAINT. IF EXCESSIVE
NOISE IS FOUND, REPLACE THE PUMP AND RETURN TO FANUC ROBOTICS AMERICA.
KEY
PUMP INPUT SHAFT
DYNAMIC SEALS
SEAL PLATE
[ET-5093-890-007] REV A
1K PUMP SHEET 2 OF 2
-171-
Figure 8-3 ET-6102-890-007 Sheet 1 of 2, ZENITH PUMP MAINTENANCE
WARNING
injure personnel or damage equipment
WARNING
4X SSHCM006100020G before you perform any service or
MUST BE IN PLACE maintenance procedures. Otherwise,
PRIOR TO INSTALLATION you could injure personnel or damage
EO-4696-526-000 equipment.
INSTALLED IN ARM
PRIOR TO MATING SCREWS SHOULD BE IN PLACE UNLESS OTHERWISE NOTED:
WITH EO-4696-521-000 AND CAPTURED BY O-RINGS SEE EG-00008 FOR LOCTITE REQUIREMENTS
PRIOR TO INSTALLATION SEE EG-00010 FOR TORQUE SPECIFICATIONS
4X SSHCM006100055S
TORQUE PER EG-0010
(9.2 N-m, 6.8 FT-LB)
EO-4696-512-001 PRIOR TO INSTALLATION
PUMP SHAFT RETAINER
EO-6102-521-000

PUMP - SEE NOTE 2

2X SSHCM006100035G
PUMP DRIVE SHAFT
EXPLODED ISO VIEW

SCALE 1:5
NOTES:
ASSEMBLY NOTES:
1. UNLESS OTHERWISE SPECIFIED TORQUE ALL FASTNERS PER EG-00010.
2. THE FOLLOWING STEPS SHOULD BE FOLLOWED TO INSTALL THE KEY IN 1. INSTALL P/I CABLE (EE-4696-267-002) INTO CORD GRIP (CGRPO000000398O)
THE KEYWAY ON THE PUMP SHAFT.
a. APPLY LOCTITE PRIMER 'N' TO KEY & KEYWAY. WAIT 30 SECONDS. 2. INSTALL PUMP QD ASM (EO4696-526-000) INTO OUTER ARM (EO4696-021-001A)
b. APPLY A SMALL AMOUNT OF LOCTITE 680 TO KEYWAY ON PUMP SHAFT.
CAUTION: PRODUCT CURES QUICKLY 3. INSTALL PUMP DRIVE SHAFT ONTO PUMP MOTOR OUTPUT SHAFT IN OUTER ARM
c. IMMEDIATELY INSTALL KEY IN KEYWAY.
d. IMMEDIATELY WIPE ALL EXCESS LIQUID FROM PUMP SHAFT. 4. INSTALL PUMP SHAFT RETAINER (EO-4696-512-001) AS NOTED INTO OUTER ARM (EO4696-021-001A)
3. PLUG UNUSED RETAINER MOUNTING HOLES
4. CAP PILOT LINES USING CAPMO000000101O FOR STORAGE OF THIS 5. INSTALL GEAR PUMP (EO-4657-511-000) ONTO PUMP MANIFOLD (EO-4696-521-000)
SUBASSEMBLY
6. INSTALL PUMP MANIFOLD (EO-4696-521-000) AND GEAR PUMP (EO-4657-511-000) INTO OUTER ARM (EO4696-021-001A)
Standard Hardware Descriptions

SSHCM006100020G M6 X 1.0 X 20mm LG. Glass Filled Nylon Socket Head Cap
[ET-6102-890-007] REV A
ZENITH PUMP MAINTENANCE SHEET 1 OF 2
-172-
WARNING

WARNING
KEY
PUMP INPUT SHAFT
DYNAMIC SEALS
SEAL PLATE
[ET-6102-890-007] REV A
-173-
8.2.1 Schematics
Figure 8-5 EG-00384 Sheet 1 of 4, P-700 2K 1+1 SCHEMATIC - VAR. REG.
WARNING
REG1 4mm
2 3 procedures when you install or remove
I/P G1/4 CPX/MPA - EO5093-110-001D SHOWN components. Otherwise you could
REG1 injure personnel or damge equipment
TDUCO000000004 O MPA10-24
1 WARNING
PORT 82/84 MPA10-17 Always disconnect power to the robot
SUPPLY PLATE before you perform any service or
REG2 4mm
3 maintenance procedures. Otherwise,
2 I/P G1/4 MPA10-16 you could injure personnel or damage
PORT 1 equipment.
REG2
TDUCO000000004 O MPA10-09
EO-5093-531-000
1 SEE EG-00008 FOR LOCTITE REQUIREMENTS

MPA10-02
6 mm
MPA10-01 SEE EG-00010 FOR TORQUE SPECIFICATIONS
6 mm PORT 3/5 PORT 1

MPA10-24 - PLUGGED
MPA10-23 - PLUGGED
MPA10-22 - PLUGGED
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
MPA10-17 - pC1 4mm
PORT 1
SUPPLY PLATE
6 mm
MPA10-16 - PLUGGED
MPA10-15 - PLUGGED
MPA10-14 - pFLUSH2 4mm CPX/MPA

MPA10-13 - pSOL2 4mm
MPA10-12 - PLUGGED
MPA10-11- SEAL 6mm

3X FITCO000001381O
THRU INNER ARM
WALL MPA10-10 - pFLUSH 4mm
PORT 10 mm
MPA10-09 - pDUMP 4mm 3/5
MPA10-08 - pCC 4mm
PORT 6 mm
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
MPA10-05 - pBW 4mm PORT 1
FITMO000002096O
MPA10-04 - pIW 4mm
TO PROCESS CONTROL MANIFOLD ASM
MPA10-03 - pPE 4mm

MPA10-02 - BRAKE 6mm
MPA10-01 - pTRIG 4mm
6 mm
6 mm
3 6 mm
TURB2 10mm
TURB1 10mm 2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004 O 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
OUT IN
D/Q -
SA2 10mm EO-4696-110-008 CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O
D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
SENSO000000466O BEAR 8mm
[EG-00384] REV E1
P-700 2K 1+1 SCHEMATIC - VAR. REG. SHEET 1 OF 4
-174-
WARNING
RESIN OUTLET PRESSURE (P1OP) extreme care and follow proper lifting
CATALYST OUTLET PRESSURE (P2OP) components. Otherwise you could
RESIN INLET FLOW METER (P1IM)
SEE NOTE 1
WARNING
REG1
MIX ELEMENT HOLDER maintenance procedures. Otherwise,
EO-5093-516-011 you could injure personnel or damage
equipment.

PAINT LINE TO BELL SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO-5093-516-010 EO-5093-516-002 C1 EO-5093-516-008
PUMP BLOCK SUPPLY BLOCK DUMP BLOCK SEE EG-00010 FOR TORQUE SPECIFICATIONS
CC RES
AIR
PUMP1
(RESIN)
EO-5093-516-004 PE
REGULATOR BLOCK
FLOW METERS SOL
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST)
SOL2 BW
FLUSH2
ESTCODE WASH LINE TO BELL

H1
SOL
SOL
HS1
PS1
PR1
SOL2
AIR
REG2
DUMP TO WASTE
RECLAIMATION
CATALYST INLET FLOW METER (P2IM)

SOL SEE NOTE 1
NOTES:
1. INLET FLOW METERS (EO-5093-516-004) ARE REPLACED WITH INLET
PRESSURE SENSORS (EO-5093-516-006) IN SOME CONFIGURATIONS. THE INLET
SENSOR LABELS (P1IM & P2IM) ARE REPLACED WITH P1IP & P2IP.
EO5093-895-003J SHOWN
CIRCULATING RESIN
NON-CIRCULATING CATALYST
VARIABLE PRESSURE REGULATORS
INLET FLOW METERS
[EG-00384] REV E1
-175-
WARNING
EO5093-895-003J SHOWN injure personnel or damge equipment
CIRCULATING RESIN
NON-CIRCULATING CATALYST WARNING
VARIABLE PRESSURE REGULATORS Always disconnect power to the robot
INLET FLOW METERS before you perform any service or
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
FIBER FIBER EE-5405-163-003
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
EE-5093-406-001 PURGED UNPURGED HAZARDOUS
24V AREA
PNEUMATICS COLUMN PURGED CARRIAGE CLASS 1
RAIL ENTRANCE DIVISION 1
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
EE-5093-424-001 1m
CASCADE EE-4696-625-003 QD
CBLEo000000365o 1.5m I/P MPPES 4-20mA REG 2 Z787 EE-5093-428-001 90Deg P1IM
24V 9 EE-5093-410 +V 6 8G1 (AW CABLE/4/T/8 ) conn
CBLEo000000363o 1ft I/P MPPE 4-20mA TURB.
SPD
0V 10 PHOENIX 0V 4 7 2 AW FLOWMETER
SIG+ 14 FREQ. XDUCER Fin 3 5 4
X2 X1
AO2 CBLEo000000365o 1.5m I/P MPPES 4-20mA REG 1 SIG- 16 R
8 1
R P1OP
X4 X3 7G 2 EE-4696-267-004
HONEYWELL SENS
6 3
5.1K Ohm RESISTORS 4
X2 X1 5
AO2
TYP (4) PL MARKED "R"
PUT LEADS & WIRES IN
8 1
P2OP
7G 2
X4 X3 SAME WIRE BARREL EE-4696-267-004
EE-5093-426-001 1m HONEYWELL SENS
6 3
5 4
CBLEo000000366o
P/I 4-20mA
SHAPE
AIR 24V 9 EE-5093-410 +V 6
EE-5093-428-001
90Deg
conn
P2IM
8G1 (AW CABLE/4/T/8 )
X2 X1 BEARING 0V 10 PHOENIX 0V 4 7 2
AI4 CBLEo000000366o P/I 4-20mA AW FLOWMETER
AIR SIG+ 14 FREQ. XDUCER Fin
3 5 4
X4 X3 SIG- 16 R R REF
EE-5093-426-001 1m EE-4560-654-003 DUAL FIBER
X2 X1
AI4
X4 X3 EE-5093-424-001 1m
EE-4696-020
EE-4560-
KEYENCE 655-002
8IN/8OUT
EE-5093-424-001 1m 4-20mA 24V 9 EE-4696-010 4 BLUE
CPX
526257 0V 10 PHOENIX 5 BLK
SPD+ 14 FREQ. XDUCER 6 BRN
MS PS
NS PL
IO SF
SPD- 16
M
COLOR VALVES BELL SPEED, 4-20mA
NOTES:
EE-5093-411-001 USE EXCESS LENGTH OF KEYENCE
PIGTAIL TO MAKE JUMPER CABLES
FOR CONNECTING PHOENIX UNITS
TO Z787 BARRIERS
JUMPER THE I.S. GND TERMS
ON THE Z787 BARRIERS, 16AWG MIN
EE-5093-432-001
COLOR VALVES
KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
NOTES
ONLY ITEMS SHOWN WITHIN THE PURGED ENCLOSURE ARE PART OF THE PROCESS ASSEMBLY
REGULATOR CABLE LENGTHS SET FOR 24-3
EE-5093-457
[EG-00384] REV E1
-176-
WARNING
EO5093-895-003M SHOWN
CIRCULATING RESIN
WARNING
VARIABLE PRESSURE REGULATORS before you perform any service or
INLET PRESSURE SENSORS maintenance procedures. Otherwise,
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-406-001
EE-5093-301-0xx
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
ESTAT
CONTROL
P HH
CASCADE EE-5093-406-001 PURGED UNPURGED HAZARDOUS
24V EE-5151-014-001
DIAM. 14.7mm(0.58in) HC-DD 24
B6 HOUSING
REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
CBLEo000000365o 1.5m I/P MPPES 4-20mA REGULATOR 2
Z787 P1IP
8 1
CBLEo000000363o 1ft 4-20mA 7 2 EE-4696-267-004
I/P MPPE 4-20mA TURBINE SPD 6 G3 HONEYWELL I/P
X2 X1 5 4
AO2 CBLEo000000365o 1.5m
I/P MPPES 4-20mA REGULATOR 1 8 1
P1OP
X4 X3 7 2 EE-4696-267-004
HONEYWELL I/P
6 G 3
X2 X1 5 4
AO2 P2OP
X4 X3 EE-5093-426-001 1m 8 1
7 2 EE-4696-267-004
EE-5093-426-001 1m HONEYWELL I/P
6 G 3
5 4
CBLEo000000366o 1m
P/I 4-20mA SHAPE AIR 8 1
P2IP
X2 X1 7 2 EE-4696-267-004
AI4 CBLEo000000366o 1m P/I 4-20mA BEARING AIR 6 G 3 HONEYWELL I/P
5 4
X4 X3 REF
EE-5093-426-001 1m EE-4696-020 EE-4560-654-003 DUAL FIBER
X2 X1
AI4 KEYENCE
X4 X3 EE-5093-426-001 1m
EE-4560-
655-002
8IN/8OUT
EE-5093-424-001 1m
24V 9 EE-4696-010 4 BLUE
CPX
526257 0V 10 PHOENIX 5 BLK
MS PS
NS PL
IO SF
SPD- 16
M
COLOR VALVES BELL SPD 4-20mA

EE-5093-411-001 NOTE: JUMPER THE I.S. GND TERMS
COLOR VALVES EE-5093-432-001

KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00384] REV E1
-177-
Figure 8-9 EG-00385 Sheet 1 of 3, P-700 1K WITH FIX REG SCHEMATICS
WARNING
FITCO000001381O (TYP) - components. Otherwise you could
THROUGH INNER ARM WALL CPX/MPA - EO5093-110-001C SHOWN injure personnel or damge equipment
MPA10-40 - pC24 4mm

MPA10-39 - pC23 4mm WARNING
MPA10-38 - pC22 4mm Always disconnect power to the robot
MPA10-37 - pC21 4mm MPA10-40 before you perform any service or
MPA10-36 - pC20 4mm
MPA10-35 - pC19 4mm you could injure personnel or damage
equipment.
MPA10-34 - pC18 4mm MPA10-33
MPA10-33 - pC17 4mm
MPA10-32 - pC16 4mm UNLESS OTHERWISE NOTED:
MPA10-31 - pC15 4mm SEE EG-00008 FOR LOCTITE REQUIREMENTS
MPA10-30 - pC14 4mm
MPA10-29 - pC13 4mm
MPA10-28 - pC12 4mm
MPA10-27 - pC11 4mm PORT 82/84 MPA10-17
MPA10-26 - pC10 4mm
SUPPLY PLATE
MPA10-25 - pC9 4mm
MPA10-24 - pC8 4mm MPA10-16
PORT 1
MPA10-23 - pC7 4mm
MPA10-22 - pC6 4mm MPA10-09
MPA10-21 - pC5 4mm
MPA10-20 - pC4 4mm MPA10-02

MPA10-19 - pC3 4mm MPA10-01
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
SUPPLY PLATE
PORT 3/5 PORT 1
MPA10-16 - p2T 4mm
MPA10-15 - PLUGGED
CPX/MPA
TO PROCESS CONTROL MANIFOLD ASM EO-5093-530-000
MPA10-14 - PLUGGED
MPA10-13 - pVENT 4mm
MPA10-12 - pDUMP2 4mm
MPA10-11- SEAL 6mm
MPA10-10 - pFLUSH 4mm 10 mm

PORT
MPA10-08 - pCC 4mm 6 mm
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002096O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm
TURB1 10mm
2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
OUT IN
D/Q -
SA2 10mm
EO-4696-110-008 CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
[EG-00385] REV C1
P-700 1K WITH FIX REG SCHEMATICS SHEET 1 OF 3
-178-
WARNING
WARNING
SOL
DUMP2
RECOVERY
DUMP you could injure personnel or damage
RECOVERY
PS4 PR4 PS2 PR2 equipment.
pC4 pC2
pDUMP PAINT
SOLV/AIR pDUMP2 PAINT ENABLE UNLESS OTHERWISE NOTED:
pPE SEE EG-00008 FOR LOCTITE REQUIREMENTS
pTRIG
pSOL FIXED
REGULATOR
15 PSI OR pIW
30 PSI INJECTOR
AIR 0-500 PSI WASH TRIGGER
P/I
pAIR pBW
p2T
BELL WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH
FLUID DELIVERY SCHEMATIC

1K GEAR PUMP W/ FIXED REGULATOR
[EG-00385] REV C1
-179-
WARNING
WARNING
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
FIBER FIBER FIBER EE-5405-163-003
COLUMN 1
EE-5093-401-001
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V EE-5151-014-001
B6 HOUSING
REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
EE-5093-426-001 1m
CBLEo000000366o
P/I 4-20mA SHAPE AIR
CBLEo000000363o 1ft
I/P MPPE 4-20mA TURBINE SPD
X2 X1
AO2 Z787
X4 X3 1K PRES
CBLEo000000366o 8 1 EE-4696-267-004
P/I 4-20mA BEARING AIR 4-20mA
X2 X1 7 2 HONEYWELL I/P
G
5 4 REF
AI4
X4 X3
EE-5093-424-001 1m 4-20mA 24V 9 EE-4696-010 4 BLUE EE-4696-020
EE-4560-654-003 DUAL FIBER
0V 10 PHOENIX 5 BLK
8IN/8OUT SPD+ 14 FREQ. XDUCER 6 BRN KEYENCE
SPD- 16
526257 BELL SPEED, 4-20mA
CPX EE-4560-
EE-5093-411-001
655-002
MS PS
NS PL
IO SF
M
COLOR VALVES
KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR EE-5093-452
CONTROLS
[EG-00385] REV C1
-180-
Figure 8-12 EG-00387 Sheet 1 of 4, P-700 2K 1+1 SCHEMATIC - FIXED REG.
WARNING
CPX/MPA - EO5093-110-001E SHOWN
MPA10-24
WARNING
PORT 82/84 MPA10-17 you could injure personnel or damage
SUPPLY PLATE equipment.
MPA10-16
PORT 1 UNLESS OTHERWISE NOTED:
MPA10-09 SEE EG-00008 FOR LOCTITE REQUIREMENTS
MPA10-02
MPA10-01
MPA10-24 - PLUGGED
MPA10-23 - PLUGGED PORT 3/5 PORT 1
MPA10-22 - PLUGGED
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
EO-5093-531-000
MPA10-18 - PLUGGED
MPA10-17 - pC1 4mm
SUPPLY PLATE
MPA10-16 - PLUGGED
MPA10-15 - PLUGGED
MPA10-14 - pFLUSH2 4mm
CPX/MPA
MPA10-12 - PLUGGED
MPA10-11- SEAL 6mm

3X FITCO000001381O
THRU INNER ARM
PORT 10 mm
MPA10-08 - pCC 4mm
PORT 6 mm
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm
TURB1 10mm 2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
OUT IN
D/Q -
SA2 10mm EO-4696-110-008 CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O
D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
[EG-00387] REV D2
P-700 2K 1+1 SCHEMATIC - FIXED REG. SHEET 1 OF 4
-181-
WARNING
CATALYST OUTLET PRESSURE (P2OP) injure personnel or damge equipment
SEE NOTE 1 WARNING
equipment.

PAINT LINE TO BELL SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO-5093-516-010 EO-5093-516-002 C1 EO-5093-516-008
CC RES
AIR
PUMP1
(RESIN)
EO-5093-516-004 PE
REGULATOR BLOCK
FLOW METERS SOL
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST)
SOL2 BW
FLUSH2

H1
SOL
SOL
HS1
PS1
PR1
SOL2
AIR
DUMP TO WASTE
RECLAIMATION

SOL SEE NOTE 1
NOTES:

PRESSURE SENSORS (EO-5093-516-006) IN SOME CONFIGURATIONS.
EO5093-895-003H SHOWN
THE INLET SENSOR LABELS (P1IM & P2IM) ARE REPLACED WITH P1IP &
P2IP.
CIRCULATING RESIN
FIXED PRESSURE REGULATORS
INLET FLOW METERS
[EG-00387] REV D2
-182-
WARNING
EO5093-895-003H SHOWN WARNING

CIRCULATING RESIN Always disconnect power to the robot
NON-CIRCULATING CATALYST maintenance procedures. Otherwise,
FIXED PRESSURE REGULATORS equipment.
INLET FLOW METERS UNLESS OTHERWISE NOTED:
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-306-0XX
ESTAT
CONTROL
EE-5093-106-00X
P HH
CASCADE SEAL
P
24V REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
Z787 EE-5093-428-001 P1IM
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
EE-5093-424-001 1m
EE-5093-426-001 1m SIG+ 14 FREQ. XDUCER Fin 3 5 4
R R
SIG- 16 P1OP
8 G 1
7 2 EE-4696-267-004
HONEYWELL SENS
CBLEo000000363o 1ft 5.1K Ohm RESISTORS 6 3
X2 X1 I/P MPPE 4-20mA TURB
SPD
TYP (4) PL MARKED "R" 5 4
8 1
P2OP
X4 X3 AO2 SAME WIRE BARREL 7 G EE-4696-267-004
2
CBLEo000000366o 1m SHAPE 3 HONEYWELL SENS
P/I 4-20mA 6
AIR 5 4
AI4 EE-5093-428-001 P2IM
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
X2 X1 CBLEo000000366o 1m BEARING 0V 10 PHOENIX 0V 4 7 2 AW FLOWMETER
P/I 4-20mA AIR SIG+ 14 FREQ. XDUCER Fin 3 5 4 REF
X4 X3 R R
EE-5093-426-001 1m SIG- 16 EE-4560-654-003 DUAL FIBER
X2 X1
X4 X3
EE-5093-424-001 1m
AI4 EE-4696-020
KEYENCE EE-4560-
8IN/8OUT 655-002
BLUE
526257 EE-5093-424-001 1m 4-20mA
24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
PS
SF
PL
M
NOTES:
EE-5093-411-001
USE EXCESS LENGTH OF KEYENCE
TO Z787 BARRIERS
KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
EE-5093-458
ONLY ITEMS SHOWN WITHIN THE PURGED CAVITY ARE PART OF THE PROCESS ASSEMBLY
[EG-00387] REV D2
-183-
WARNING
WARNING
EO5093-895-003L SHOWN Always disconnect power to the robot
CIRCULATING RESIN before you perform any service or
NON-CIRCULATING CATALYST you could injure personnel or damage
equipment.
INLET PRESSURE SENSORS UNLESS OTHERWISE NOTED:
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
EE-5093-306-0XX
CASCADE
P
24V REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3
HIGH VOLTAGE CBL
Z787 P1IP
8 1 EE-4696-267-004
EE-5093-426-001 1m 4-20mA 7 2 HONEYWELL I/P
EE-5093-426-001 1m 6 G 3
5 4
P1OP
CBLEo000000366o 8 1 EE-4696-267-004
6 G 3 HONEYWELL I/P
X2 X1 5 4
CBLEo000000363o 1ft I/P MPPE 4-20mA TURBINE SPD
X4 X3
P2OP
AO2 8 1 EE-4696-267-004
7 2 HONEYWELL I/P
6 G 3
5 4
AI4 BEARING AIR P2IP
CBLEo000000366o P/I 4-20mA 8 1
EE-4696-267-004
6 G 3
5 4
X4 X3
X2 X1
AI4 KEYENCE
X4 X3 EE-5093-426-001 1m
EE-4560-
655-002
8IN/8OUT
BLUE
526257 EE-5093-424-001 1m 4-20mA 24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
SF
PS
PL
M

EE-5093-411-001
NOTE: JUMPER THE I.S. GND TERMS
COLOR VALVES
EE-5093-432-001
KATES
EE-5093-456
CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00387] REV D2
-184-
Figure 8-16 EG-00388 Sheet 1 of 4, MULTIRESIN 2K SCHEMATIC - VAR. REG.
WARNING
I/P G1/4 3 CPX/MPA - EO5093-110-001H SHOWN extreme care and follow proper lifting
REG1 4mm 2 procedures when you install or remove
TDUCO000000004O components. Otherwise you could
REG1
FITCO000001381O 1 MPA10-48
THRU INNER ARM WALL WARNING
I/P G1/4 3 before you perform any service or
REG2 4mm
2 maintenance procedures. Otherwise,
TDUCO000000004O you could injure personnel or damage
PORT 82/84 equipment.
REG2 MPA10-25
24X FITCO000001381O 1 SUPPLY PLATE
THRU INNER ARM WALL UNLESS OTHERWISE NOTED:
EO-5093-531-000
PORT 1 SEE EG-00010 FOR TORQUE SPECIFICATIONS
MPA10-16
6 mm
MPA10-25 - pC1
MPA10-17
THRU
MPA10-48 - pC24
MPA10-09
6 mm
3X FITCO000001381O
THRU INNER ARM WALL PORT 1
SUPPLY PLATE MPA10-02
6 mm MPA10-01
MPA10-24 - PLUGGED
MPA10-23 - pH3 4mm
MPA10-22 - pH2 4mm
MPA10-21 - pH1 4mm

PORT 3/5 PORT 1
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
FITCO000001381O MPA10-17 - pWASH 4mm
THRU INNER ARM
WALL
MPA10-16 - p2T 4mm
CPX/MPA
2X FITCO000001381O MPA10-14 - pFLUSH2 4mm
THRU AXIS 3 6 mm
HOUSING
6 mm
3X FITCO000001381O MPA10-11- SEAL 6mm

THRU INNER ARM
WALL
PORT
PORT
MPA10-07 - pAIR 4mm
82/84
MPA10-06 - pSOL 4mm
10 mm
EXHAUST MANIFOLD -
MPA10-04 - pIW 4mm
FITMO000002096O
MPA10-03 - pPE 4mm

6 mm
3
TURB2 10mm
TURB1 10mm
2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004O
6 mm
SA1 10mm
OUT IN
10 mm
D/Q - EXHAUST TO
SA2 10mm
EO-4696-110-008 BOOTH
CPX - 10MM
SUPPLY MANIFOLD
8 mm
EO-5093-170-025
BEAR 6mm
TBSP1 - 10MM
CARRIAGE AIR
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
SENSO000000466O BEAR - 8MM
[EG-00388] REV E1
MULTIRESIN 2K SCHEMATIC - VAR. REG. SHEET 1 OF 4
-185-
WARNING
RESIN OUTLET PRESSURE (P1OP) procedures when you install or remove
RESIN INLET FLOW METER (P1IM) MIX ELEMENT HOLDER injure personnel or damge equipment
CATALYST OUTLET PRESSURE (P2OP) SEE NOTE 1 EO-5093-516-011
WARNING
ESTCODE PAINT LINE TO BELL Always disconnect power to the robot
EO-5093-516-010 EO-5093-517-004 EO-5093-517-002 EO-5093-517-008 before you perform any service or
PUMP BLOCK REGULATOR BLOCK SUPPLY BLOCK DUMP BLOCK maintenance procedures. Otherwise,
FLOW METERS you could injure personnel or damage
equipment.
DUMP2 RES
PUMP1 SEE EG-00008 FOR LOCTITE REQUIREMENTS
(RESIN) SEE EG-00010 FOR TORQUE SPECIFICATIONS
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

REG2
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
RESIN FROM INNER ARM
SEE NOTE 1 DUMP TO WASTE
PR24
PS24
PR22
PS22
REG
PR2
PS2
RECLAIMATION
PS4
PR4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
2T
NOTES:
1. INLET FLOW METERS (EO-5093-517-004) ARE REPLACED
WITH INLET PRESSURE SENSORS (EO-5093-517-006) IN
SOME CONFIGURATIONS. THE INLET SENSOR LABELS
PR1
PS1
PR21
PS21
PR23
PS23
PS3
PR3
(P1IM & P2IM) ARE REPLACED WITH P1IP & P2IP.

2T
EO-5093-510-001
CIRCULATING COLOR STACK
ADDITIONAL COLOR SLICES HERE EO5093-895-004AT SHOWN
(24) RESIN - CIRCULATING
(3) CATALYST - CIRCULATING
INLET FLOW METERS
[EG-00388] REV E1
-186-
WARNING
EO5093-895-004AT SHOWN components. Otherwise you could
(3) CATALYST - CIRCULATING WARNING
INLET FLOW METERS maintenance procedures. Otherwise,
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
ESTAT
CONTROL
P HH
CASCADE SEAL
P
24V AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
EE-5093-424-001 1m
CBLEo000000365o 1.5m I/P MPPES 4-20mA REG 2
Z787 EE-5093-428-001 90Deg P1IM
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 ) conn
CBLEo000000363o 1ft I/P MPPE 4-20mA TURB.
SPD
X2 X1 R R
AO2 CBLEo000000365o 1.5m SIG- 16 P1OP
I/P MPPES 4-20mA REG 1 8 1
X4 X3 7G 2 EE-4696-267-004
HONEYWELL SENS
5.1K Ohm RESISTORS 6 3
X2 X1 TYP (4) PL MARKED "R" 5 4
AO2 PUT LEADS & WIRES IN
8
P2OP
SAME WIRE BARREL 1
7G
X4 X3 EE-4696-267-004
EE-5093-426-001 1m 2 HONEYWELL SENS
6 3
5 4
CBLEo000000366o SHAPE 90Deg P2IM
P/I 4-20mA AIR 24V 9 EE-5093-428-001 conn
EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
X2 X1 BEARING 0V 10 PHOENIX 0V 4 7 2
AI4 CBLEo000000366o P/I 4-20mA AW FLOWMETER
AIR SIG+ 14 FREQ. XDUCER Fin 3 5 4
X4 X3 SIG- 16 R R REF
EE-5093-426-001 1m EE-4560-654-003 DUAL FIBER
X2 X1
AI4
X4 X3 EE-5093-424-001 1m
EE-4696-020
EE-4560-
KEYENCE 655-002
8IN/8OUT
BLUE
526257 EE-5093-424-001 1m 4-20mA 24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
SF
PL
PS
M
NOTES:
EE-5093-411-001 USE EXCESS LENGTH OF KEYENCE
TO Z787 BARRIERS
EE-5093-432-001
COLOR VALVES
KATES CONTROL VALVE

CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
EE-5093-457
SHAPING AIR
CONTROLS
NOTES
[EG-00388] REV E1
-187-
WARNING
EO5093-895-004F SHOWN components. Otherwise you could
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-406-001
EE-5093-301-0xx
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-306-0XX
ESTAT
CONTROL
EE-5093-106-00X
P HH
24V EE-5151-014-001
B6 HOUSING
REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
CBLEo000000365o 1.5m I/P MPPES 4-20mA REGULATOR 2
Z787 P1IP
8 1
CBLEo000000363o 1ft 4-20mA 7 2 EE-4696-267-004
I/P MPPE 4-20mA TURBINE SPD 6 G3 HONEYWELL I/P
X2 X1 5 4
AO2 CBLEo000000365o 1.5m
I/P MPPES 4-20mA REGULATOR 1 P1OP
8 1
X4 X3 7 2 EE-4696-267-004
HONEYWELL I/P
6 G 3
X2 X1 5 4
X3
AO2 P2OP
X4 EE-5093-426-001 1m 8 1
7 2 EE-4696-267-004
EE-5093-426-001 1m HONEYWELL I/P
6 G 3
5 4
CBLEo000000366o 1m P2IP
X2 7 2 EE-4696-267-004
X1 AI4 CBLEo000000366o 1m HONEYWELL I/P
P/I 4-20mA BEARING AIR 6 G 3
5 4
X4 X3 REF
X2 X1
AI4 KEYENCE
X4 X3 EE-5093-426-001 1m
EE-4560-
655-002
8IN/8OUT
BLUE
526257 EE-5093-424-001 1m
24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
PS
SF
PL
M
COLOR VALVES BELL SPD 4-20mA

EE-5093-411-001 NOTE: JUMPER THE I.S. GND TERMS

KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00388] REV E1
-188-
Figure 8-20 EG-00389 Sheet 1 of 4, MULTIRESIN 2K SCHEMATIC - FIX REG
WARNING
CPX/MPA - EO5093-110-001L SHOWN components. Otherwise you could
MPA10-48 WARNING
equipment.
PORT 82/84
24X FITCO000001381O
THRU INNER ARM WALL MPA10-25 UNLESS OTHERWISE NOTED:
SUPPLY PLATE SEE EG-00008 FOR LOCTITE REQUIREMENTS
MPA10-24
PORT 1
MPA10-25 - pC1
EO-5093-531-000
THRU MPA10-16 MPA10-17

MPA10-48 - pC24
3X FITCO000001381O MPA10-09
THRU INNER ARM WALL SUPPLY PLATE
MPA10-24 - PLUGGED
MPA10-02
MPA10-23 - pH3 4mm
MPA10-01
MPA10-22 - pH2 4mm
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm

PORT 3/5 PORT 1
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
THRU INNER ARM
WALL
MPA10-16 - p2T 4mm
CPX/MPA
THRU AXIS 3
HOUSING
3X FITCO000001381O MPA10-11- SEAL 6mm

THRU INNER ARM
WALL
PORT
PORT
MPA10-07 - pAIR 4mm
EXHAUST MANIFOLD -
82/84
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm

6 mm
3
TURB2 10mm
TURB1 10mm
2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004O EXHAUST TO
10 mm
BOOTH
6 mm
SA1 10mm
OUT IN
D/Q -
SA2 10mm
EO-4696-110-008
CPX - 10MM
SUPPLY MANIFOLD
8 mm
EO-5093-170-025
BEAR 6mm
TBSP1 - 10MM
CARRIAGE AIR
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
SENSO000000466O BEAR - 8MM
[EG-00389] REV E2
MULTIRESIN 2K SCHEMATIC - FIX REG SHEET 1 OF 4
-189-
RESIN OUTLET PRESSURE (P1OP)

WARNING
CATALYST OUTLET PRESSURE (P2OP) procedures when you install or remove
SEE NOTE 1 EO-5093-516-011
WARNING
equipment.
DUMP2 RES
(RESIN) SEE EG-00010 FOR TORQUE SPECIFICATIONS
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
PR2
PS2
RECLAIMATION
PS4
PR4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
NOTES:
2T 1. INLET FLOW METERS (EO-5093-517-004) ARE REPLACED
WITH INLET PRESSURE SENSORS (EO-5093-517-006) IN SOME
CONFIGURATIONS. THE INLET SENSOR LABELS (P1IM & P2IM)
ARE REPLACED WITH P1IP & P2IP.
PR1
PS1
PR21
PS21
PR23
PS23
PS3
PR3
2T
EO-5093-510-001
ADDITIONAL COLOR SLICES HERE EO5093-895-004BT SHOWN
INLET FLOW METERS
[EG-00389] REV E2
-190-
WARNING
EO5093-895-004BT SHOWN WARNING

(24) RESIN - CIRCULATING Always disconnect power to the robot
(3) CATALYST - CIRCULATING maintenance procedures. Otherwise,
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
ESTAT
CONTROL
P HH
CASCADE
SEAL
P
24V REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3 REF
HIGH VOLTAGE CBL
Z787 EE-5093-428-001 P1IM
24V 9 EE-5093-410 +V 6 8G1 (AW CABLE/4/T/8 )
EE-5093-424-001 1m
EE-5093-426-001 1m SIG+ 14 FREQ. XDUCER Fin 3 5 4
R R
SIG- 16 P1OP
8 G 1
7 2 EE-4696-267-004
HONEYWELL SENS
CBLEo000000363o 1ft 5.1K Ohm RESISTORS 6 3
X2 X1 I/P MPPE 4-20mA TURB
SPD
8 1
P2OP
X4 X3 AO2 SAME WIRE BARREL 7 G EE-4696-267-004
2
CBLEo000000366o 1m SHAPE 3 HONEYWELL SENS
P/I 4-20mA 6
AIR 5 4
AI4 EE-5093-428-001 P2IM
24V 9 EE-5093-410 +V 6 8G1 (AW CABLE/4/T/8 )
X2 X1 CBLEo000000366o 1m P/I BEARING 0V 10 PHOENIX 0V 4 7 2 AW FLOWMETER
4-20mA AIR SIG+ 14 FREQ. XDUCER Fin 3 5 4 REF
X4 X3 R R
EE-5093-426-001 1m SIG- 16 EE-4560-654-003 DUAL FIBER
X2 X1
X4 X3
EE-5093-424-001 1m
AI4 EE-4696-020
KEYENCE EE-4560-
8IN/8OUT 655-002
BLUE
526257 EE-5093-424-001 1m 4-20mA
24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
PS
SF
PL
M
NOTES:
EE-5093-411-001
TO Z787 BARRIERS
KATES CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
EE-5093-458
[EG-00389] REV E2
-191-
WARNING
WARNING
EO5093-895-004AF SHOWN Always disconnect power to the robot
(24) RESIN - CIRCULATING maintenance procedures. Otherwise,
(3) CATALYST - CIRCULATING equipment.
FIXED PRESSURE REGULATORS UNLESS OTHERWISE NOTED:

INLET PRESSURE SENSORS SEE EG-00008 FOR LOCTITE REQUIREMENTS
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
EE-5093-306-0XX
CASCADE
P
24V REV B AREA
GROUP C,E,E,F
I.S. GROUND
EE-4696-272-002
REF
EE-4560-653-002
JOINT 3
HIGH VOLTAGE CBL
Z787 P1IP
8 1 EE-4696-267-004
EE-5093-426-001 1m 4-20mA 7 2 HONEYWELL I/P
EE-5093-426-001 1m 6 G 3
5 4
P1OP
CBLEo000000366o 8 1 EE-4696-267-004
P/I 4-20mA SHAPE AIR 7 2 HONEYWELL I/P
6 G 3
X2 X1 5 4
CBLEo000000363o 1ft I/P MPPE 4-20mA TURBINE SPD
X4 X3
P2OP
AO2 8 1 EE-4696-267-004
7 2 HONEYWELL I/P
6 G 3
5 4
AI4 BEARING AIR P2IP
CBLEo000000366o P/I 4-20mA 8 1 EE-4696-267-004
6 G 3
5 4
X4 X3
X2 X1
AI4 KEYENCE
X4 X3 EE-5093-426-001 1m
EE-4560-
655-002
8IN/8OUT
BLUE
526257 EE-5093-424-001 1m 4-20mA 24V 9 EE-4696-010 4 BLK
CPX 0V 10 PHOENIX 5
MS
NS
IO
SPD- 16
PS
SF
PL
M

EE-5093-411-001
COLOR VALVES
EE-5093-432-001
KATES
EE-5093-456
CONTROL VALVE
CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00389] REV E2
-192-
Figure 8-24 EG-00401 Sheet 1 of 3, 1K FESTO WITH REG SCHEMATICS
WARNING
REG1 4mm procedures when you install or remove
I/P G1/8 components. Otherwise you could
FITCO000001381O (TYP) -
THROUGH CARRIAGE REG1 CPX/MPA - EO5093-110-001C SHOWN injure personnel or damge equipment
TDUCO000000007O
MPA10-40 - pC24 4mm
MPA10-36 - pC20 4mm
equipment.
MPA10-34 - pC18 4mm MPA10-33
MPA10-33 - pC17 4mm
6 mm
MPA10-32 - pC16 4mm
MPA10-30 - pC14 4mm
MPA10-29 - pC13 4mm
MPA10-28 - pC12 4mm
MPA10-27 - pC11 4mm PORT 82/84 MPA10-17
MPA10-26 - pC10 4mm
SUPPLY PLATE
MPA10-25 - pC9 4mm
MPA10-24 - pC8 4mm MPA10-16
MPA10-23 - pC7 4mm
PORT 1
MPA10-22 - pC6 4mm MPA10-09
MPA10-21 - pC5 4mm
MPA10-20 - pC4 4mm MPA10-02

MPA10-19 - pC3 4mm MPA10-01
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
PORT 1
SUPPLY PLATE
6 mm PORT 3/5 PORT 1
MPA10-16 - p2T 4mm
MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - PLUGGED
MPA10-13 - PLUGGED
MPA10-11- SEAL 6mm

PORT
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
CPX - 10MM
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm I/P G1/4
TURB1 10mm
2 TURBINE
TDUCO000000004O-6 BAR 1
TDUCO000000017O-10 BAR
10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
TBSP1 - 12MM
TBSP2 - 12MM
SA2 10mm
CARRIAGE ROX
BEAR 6mm
HPNMO000019105O - SET TO 85 PSI

ONLY USED ON 10 BAR SYSTEMS
BEAR P/I 8 mm
IN PROCESS AIR SUPPLY 1 - 12mm
SENSO000000466O OUT D/Q -
EO-4696-110-011 OR
EO-6102-112-001 (5 BAR) PROCESS AIR SUPPLY 2 - 12mm
SAS 4mm SAS P/I
SENSO000000466O
BEAR 8mm
[EG-00401] REV A
1K FESTO WITH REG SCHEMATICS SHEET 1 OF 3
-193-
WARNING
WARNING
COLOR CHANGER (24 COLOR MAX) before you perform any service or
DUMP
SOL
REG RECOVERY
pC4 pC2
pDUMP PAINT
pTRIG SEE EG-00010 FOR TORQUE SPECIFICATIONS
pSOL
pIW
INJECTOR
0-500 PSI WASH TRIGGER
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

1K GEAR PUMP W/ REGULATOR
[EG-00401] REV A
-194-
WARNING
WARNING
equipment.
PURGED UNPURGED UNLESS OTHERWISE NOTED:

HAZARDOUS
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
EE-6102-211-XXX
REF
EE-6102-161-XXX I.S. GROUND EE-4696-272-001
HIGH VOLTAGE CBL
EE-4696-625-00X
EE-6102-276-XXX
EE-5093-426-001 1m JOINT 2 EE-4560-653-00X
CBLEo000000366o
CASCADE QD
CBLEo000000364o 1ft
CBLEo000000364o
I/P MPPE 4-20mA REGULATOR
X2 X1
AO2 Z787
X4 X3
REF 1K PRES
8 1 EE-4696-267-002
CBLEo000000366o 4-20mA
X2 X1
P/I 4-20mA BEARING AIR 7
G
2 HONEYWELL P/I
AI4 5 4
REF
X4 X3
EE-5093-424-001 1m 4-20mA
24V 9 EE-4696-010 4 BLUE EE-4696-020 EE-4560-654-00X
0V 10 PHOENIX 5 BLK DUAL FIBER
FREQ. XDUCER BRN KEYENCE
8IN/8OUT
SPD+ 14 6
SPD- 16
526257 EE-4560-655-001
CPX REF
EE-5093-411-001
MS PS
NS PL
IO SF
M
COLOR VALVES
COLOR VALVES
KATES CONTROL VALVE

9 PIN D
CONTROL VALVE
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
ONLY THOSE ITEMS WITHIN THE PURGED AREA ARE PART OF THE PROCESS ASSEMBLY BOM
[EG-00401] REV A
-195-
Figure 8-27 EG-00402 Sheet 1 of 3, P-500iA 1K W/ FIXED REG SCHEM
WARNING
THROUGH CARRIAGE CPX/MPA - EO5093-110-001C SHOWN injure personnel or damge equipment
MPA10-40 - pC24 4mm

MPA10-36 - pC20 4mm
equipment.
MPA10-34 - pC18 4mm MPA10-33
MPA10-33 - pC17 4mm
MPA10-30 - pC14 4mm
MPA10-29 - pC13 4mm
MPA10-28 - pC12 4mm
MPA10-27 - pC11 4mm PORT 82/84 MPA10-17
MPA10-26 - pC10 4mm
SUPPLY PLATE
MPA10-25 - pC9 4mm
MPA10-24 - pC8 4mm MPA10-16
MPA10-23 - pC7 4mm
PORT 1
MPA10-22 - pC6 4mm MPA10-09
MPA10-21 - pC5 4mm
MPA10-20 - pC4 4mm MPA10-02

MPA10-19 - pC3 4mm MPA10-01
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
SUPPLY PLATE
PORT 3/5 PORT 1
MPA10-16 - p2T 4mm
MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - PLUGGED
MPA10-13 - PLUGGED
MPA10-11- SEAL 6mm

PORT
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
CPX - 10MM
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm
2 I/P G1/4
TURB1 10mm
TURBINE 1
TDUCO000000017O-10 BAR 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
TBSP1 - 12MM
TBSP2 - 12MM
SA2 10mm
CARRIAGE ROX
BEAR 6mm

BEAR P/I 8 mm
EO-4696-110-011 OR
EO-6102-112-001 (5 BAR) PROCESS AIR SUPPLY 2 - 12mm
SAS 4mm SAS P/I
SENSO000000466O
BEAR 8mm
[EG-00402] REV A
P-500iA 1K W/ FIXED REG SCHEM SHEET 1 OF 3
-196-
WARNING
WARNING
DUMP
SOL
RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
FIXED REG pIW
15 OR 30 PSI
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

1K GEAR PUMP W FIXED REGULATOR
[EG-00402] REV A
-197-
WARNING
WARNING
equipment.
PURGED UNPURGED UNLESS OTHERWISE NOTED:
HAZARDOUS
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
EE-6102-211-XXX REF
HIGH VOLTAGE CBL
EE-6102-161-XXX I.S. GROUND EE-4696-272-001 EE-4696-625-00X
REF
EE-6102-276-XXX EE-4560-653-00X
JOINT 2
EE-5093-426-001 1m
CASCADE QD
CBLEo000000366o
CBLEo000000364o 1ft
X2 X1
AO2 Z787
X4 X3 REF 1K PRES
CBLEo000000366o 8 1 EE-4696-267-002
X2 X1
P/I 4-20mA BEARING AIR 4-20mA
7 2 HONEYWELL P/I
G
5 4
AI4 REF
X4 X3
EE-5093-424-001 1m 4-20mA
24V 9 EE-4696-010 4 BLUE EE-4696-020 REF EE-4560-654-00X DUAL FIBER
0V 10 PHOENIX 5 BLK
FREQ. XDUCER BRN KEYENCE
8IN/8OUT SPD+ 14 6
SPD- 16
526257 BELL SPEED, 4-20mA
CPX EE-4560-
655-001
MS PS
REF
NS PL
IO SF
EE-5093-411-001
COLOR VALVES
COLOR VALVES
KATES CONTROL VALVE

CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00402] REV A
-198-
Figure 8-30 EG-00410 Sheet 1 of 3, P-700 GUN OPTION 1K WITH FIX REG SCHEMATICS
WARNING
THROUGH INNER ARM WALL CPX/MPA - EO5093-110-001S SHOWN injure personnel or damge equipment
MPA10-40 - pC24 4mm

MPA10-36 - pC20 4mm
equipment.
MPA10-34 - pC18 4mm MPA10-33
MPA10-33 - pC17 4mm
MPA10-30 - pC14 4mm
MPA10-29 - pC13 4mm
MPA10-28 - pC12 4mm
MPA10-27 - pC11 4mm PORT 82/84 MPA10-17
MPA10-26 - pC10 4mm
SUPPLY PLATE
MPA10-25 - pC9 4mm
MPA10-24 - pC8 4mm
MPA10-16
MPA10-23 - pC7 4mm
PORT 1
MPA10-22 - pC6 4mm MPA10-09
MPA10-21 - pC5 4mm
MPA10-20 - pC4 4mm MPA10-02

MPA10-19 - pC3 4mm MPA10-01
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
SUPPLY PLATE
PORT 3/5 PORT 1
MPA10-16 - p2T 4mm
MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - PLUGGED
MPA10-11 - PLUGGED
MPA10-10 - pFLUSH 4mm

PORT 10 mm
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
MPA10-02 - PLUGGED
(TURB2)
10mm
6 mm
3
ATOMIZING AIR
(TURB1) FLOW SENSOR 2 I/P G1/4 10 mm
10mm
SENSO000000471O ATOMIZING AIR 1 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
(SA1) 3
10mm
I/P G1/4
FAN AIR FAN AIR
(SA2) FLOW SENSOR 2 1
10mm TDUCO000000004O
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
ATOMIZING AIR (TBSP1) - 10MM
FAN AIR (D/Q1) - 10MM
[EG-00410] REV B
P-700 GUN OPTION 1K WITH FIX REG SHEET 1 OF 3
SCHEMATICS
-199-
WARNING
WARNING
SOL
DUMP2
RECOVERY
RECOVERY
pC4 pC2
pDUMP PAINT
FIXED pTRIG SEE EG-00010 FOR TORQUE SPECIFICATIONS
pSOL
REGULATOR
15 PSI OR pIW
30 PSI INJECTOR
P/I
pAIR pBW
p2T
GUN WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

GUN OPTION 1K GEAR PUMP W/ FIXED REGULATOR
[EG-00410] REV B
SCHEMATICS
-200-
WARNING
WARNING
equipment.

EE-4696
171-00X EE-4696-171-00X SEE EG-00008 FOR LOCTITE REQUIREMENTS
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
HAZARDOUS
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
EE-5093-406-001 PURGED UNPURGED
24V EE-5151-014-001
B6 HOUSING
REV B AREA
I.S. GROUND GROUP C,E,E,F
EE-4696-272-002
EE-5093-426-001 1m
CBLEo000000374o FAN AIR

P/I 4-20mA
CBLEo000000365o
FAN AIR
JOINT 3
I/P MPPE 4-20mA
REF
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR HIGH VOLTAGE CBL
X2 X1
X4 X3
AO2
X2 X1 Z787 1K PRESSURE
X4 X3
AO2 4-20mA
8 1 EE-4696-267-004
7 2 HONEYWELL P/I 4-20mA
G
X2 X1
5 4
X4 X3
AI4 CBLEo000000374o
P/I 4-20mA ATOMIZING AIR
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
EE-5093-411-001 COLOR VALVES
[EG-00410] REV B
SCHEMATICS
-201-
Figure 8-33 EG-00411 Sheet 1 of 3, P-700 GUN OPTION 1K WITH REG SCHEMATICS
WARNING
REG1 4mm CPX/MPA - EO5093-110-001S SHOWN procedures when you install or remove
I/P G1/4 components. Otherwise you could
FITCO000001381O (TYP) -
THROUGH INNER ARM WALL REG1 injure personnel or damge equipment
TDUCO000000004O
MPA10-40 - pC24 4mm
MPA10-39 - pC23 4mm
MPA10-40 WARNING
MPA10-37 - pC21 4mm before you perform any service or
MPA10-36 - pC20 4mm MPA10-33 maintenance procedures. Otherwise,
MPA10-34 - pC18 4mm
equipment.
MPA10-33 - pC17 4mm
MPA10-25
MPA10-30 - pC14 4mm SEE EG-00010 FOR TORQUE SPECIFICATIONS
MPA10-29 - pC13 4mm PORT 82/84 MPA10-17
MPA10-28 - pC12 4mm
SUPPLY PLATE
MPA10-27 - pC11 4mm
MPA10-26 - pC10 4mm MPA10-16
6 mm
MPA10-25 - pC9 4mm
PORT 1
MPA10-24 - pC8 4mm MPA10-09
MPA10-23 - pC7 4mm
MPA10-22 - pC6 4mm MPA10-02
MPA10-21 - pC5 4mm MPA10-01
MPA10-20 - pC4 4mm
MPA10-19 - pC3 4mm
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
PORT 3/5 PORT 1
PORT 1
SUPPLY PLATE
MPA10-16 - p2T 4mm
MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - PLUGGED
MPA10-11 - PLUGGED
MPA10-10 - pFLUSH 4mm

PORT 10 mm
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
MPA10-02 - PLUGGED
(TURB2)
10mm
6 mm
3 6 mm
ATOMIZING AIR
ATOMIZING AIR 1
10mm
SENSO000000471O 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm
BOOTH
3
(SA1)
10mm
I/P G1/4
FAN AIR FAN AIR
SENSO000000471O CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00411] REV C1
P-700 GUN OPTION 1K WITH REG SHEET 1 OF 3
SCHEMATICS
-202-
WARNING
WARNING
SOL
DUMP2
RECOVERY
REG RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
pIW
INJECTOR
P/I
pAIR pBW
p2T
GUN WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

GUN OPTION 1K GEAR PUMP W/ REGULATOR
[EG-00411] REV C1
SCHEMATICS
-203-
WARNING
WARNING
equipment.
EE-4696 UNLESS OTHERWISE NOTED:

I.S. GND
171-00X
EE-4696-171-00X SEE EG-00008 FOR LOCTITE REQUIREMENTS
FROM COL 1
6.9MM I.S. GROUND SEE EG-00010 FOR TORQUE SPECIFICATIONS
PG9
ETHERNET
SW MEDIA
FIBER FIBER CONV
FIBER EE-5405-163-003
COLUMN 1
EE-5093-401-001
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
ESTAT EE-5093-106-00X EE-5093-306-0XX

CONTROL
P
CASCADE
HH
SEAL
P
24V EE-5151-014-001
B6 HOUSING
REV B AREA
ENTRANCE I.S. GROUND DIVISION 1
RAIL EE-4696-272-002
GROUP C,E,E,F
EE-5093-426-001 1m

P/I 4-20mA
CBLEo000000365o
I/P MPPE 4-20mA FAN AIR JOINT 3
CBLEo000000363o ATOMIZING AIR HIGH VOLTAGE CBL
I/P MPPE 4-20mA
CBLEo000000364o REGULATOR
I/P MPPE 4-20mA
X2 X1
X4 X3
AO2
Z787 1K PRESSURE
X2 X1
AO2 8 1 EE-4696-267-004
4-20mA HONEYWELL P/I 4-20mA
X4 X3 7 2
G
5 4
X2 X1
X4 X3
AI4 CBLEo000000374o
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
[EG-00411] REV C1
SCHEMATICS
-204-
Figure 8-36 EG-00412 Sheet 1 of 3, P-700 GUN OPTION WB SCHEMATICS
WARNING
MPA10-48 - pC24 4mm extreme care and follow proper lifting
THROUGH INNER ARM WALL MPA10-47 - pC23 4mm procedures when you install or remove
FITCO000001381O (TYP) MPA10-46 - pC22 4mm components. Otherwise you could
MPA10-45 - pC21 4mm CPX/MPA - EO5093-110-001AD SHOWN injure personnel or damge equipment
MPA10-44 - pC20 4mm
MPA10-43 - pC19 4mm

MPA10-42 - pC18 4mm
MPA10-48 WARNING
MPA10-41 - pC17 4mm
MPA10-41 before you perform any service or
MPA10-38 - pC14 4mm equipment.
MPA10-33
MPA10-37 - pC13 4mm
MPA10-36 - pC12 4mm
MPA10-35 - pC11 4mm
MPA10-34 - pC10 4mm PORT 82/84 MPA10-25 SEE EG-00010 FOR TORQUE SPECIFICATIONS
MPA10-33 - pC9 4mm
SUPPLY PLATE
MPA10-32 - pC8 4mm
MPA10-31 - pC7 4mm
PORT 1
MPA10-30 - pC6 4mm
MPA10-29 - pC5 4mm MPA10-24
MPA10-28 - pC4 4mm MPA10-16
MPA10-27 - pC3 4mm MPA10-17
MPA10-26 - pC2 4mm
MPA10-09
MPA10-25 - pC1 4mm
PORT 1 - 6mm
SUPPLY PLATE
DRY - 4mm MPA10-24 - PLUGGED
MPA10-23 - PLUGGED MPA10-02 MPA10-01
VLVLO000000032O MPA10-22 - PLUGGED
MPA10-21 - PLUGGED
MPA10-20 - pVAIR 4mm MPA10-20 - PLUGGED
MPA10-19 - pDAIR 4mm
MPA10-18 - pDI 4mm PORT 3/5 PORT 1
MPA10-17 - pVAC 4mm
MPA10-16 - p2T 4mm

MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - pPAINT 4mm

MPA10-11 - PLUGGED
MPA10-10 - pCAN 4mm PORT 10 mm

PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
MPA10-02 - PLUGGED
(TURB2)
10mm
6 mm
3
ATOMIZING AIR
ATOMIZING AIR 1
10mm
SENSO000000471O 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
(SA1)
3
10mm
I/P G1/4
FAN AIR FAN AIR
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00412] REV B
P-700 GUN OPTION WB SCHEMATICS SHEET 1 OF 3
-205-
WARNING
WARNING
equipment.

ISOCORE DUMP LINES
DUMP2 PAINT
DUMP LINE
DUMP
RECOVERY
CAN
SOL SOL2 PS4 PR4 VACUUM EXHAUST

PS2 PR2
pC4 pC2
PAINT LINE
SOLV/AIR
PAINT ENABLE
pPE
pSOL
pTRIG
pSOL2 pIW
VAC INJECTOR
AIR WASH TRIGGER
ISOLATION LINE
pAIR
pCC pBW
p2T
VAIR
GUN WASH
2T
pC3 pC1
PS3 PR3 PS1 PR1
WASH WASH LINE
[EG-00412] REV B
-206-
WARNING
WARNING
equipment.

EE-4696
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
HAZARDOUS
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V EE-5151-014-001
B6 HOUSING
REV B AREA
PNEUMATICS COLUMN CLASS 1
PURGED CARRIAGE
GROUP C,E,E,F

P/I 4-20mA
CBLEo000000365o
I/P MPPE 4-20mA ATOMIZING AIR
JOINT 3
CBLEo000000363o HIGH VOLTAGE CBL
I/P MPPE 4-20mA FAN AIR
X2 X1
X4 X3
AO2
X2 X1
X4 X3
AI4 CBLEo000000374o
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
EE-5093-411-001 COLOR VALVES
WATERBORNE
[EG-00412] REV B
-207-
Figure 8-39 EG-00413 Sheet 1 of 4, P-700 GUN OPTION 2K 1+1 SCHEMATICS - FIXED REG.
WARNING
CPX/MPA - EO5093-110-001U SHOWN
MPA10-24
WARNING
PORT 82/84 MPA10-17 you could injure personnel or damage
SUPPLY PLATE equipment.
MPA10-16
MPA10-02
MPA10-01
MPA10-24 - PLUGGED
MPA10-23 - PLUGGED PORT 3/5 PORT 1
MPA10-22 - PLUGGED
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
EO-5093-531-000
MPA10-18 - PLUGGED
MPA10-17 - pC1 4mm
SUPPLY PLATE
MPA10-16 - PLUGGED
MPA10-15 - PLUGGED
CPX/MPA
MPA10-12 - PLUGGED
MPA10-11- PLUGGED
3X FITCO000001381O
THRU INNER ARM
PORT 10 mm
MPA10-08 - pCC 4mm
PORT 6 mm
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
MPA10-02 - PLUGGED
(TURB2)
10mm
6 mm
3
ATOMIZING AIR
ATOMIZING AIR 1
10mm
SENSO000000471O 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
(SA1) 3
10mm
I/P G1/4
FAN AIR FAN AIR
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00413] REV B
P-700 GUN OPTION 2K 1+1 SCHEMATICS - SHEET 1 OF 4
FIXED REG.
-208-
WARNING
SEE NOTE 1 WARNING
equipment.

PAINT LINE TO GUN
EO-5093-516-010 EO-5093-516-002 EO-5093-516-008 SEE EG-00008 FOR LOCTITE REQUIREMENTS
C1
CC RES
AIR
PUMP1
(RESIN)
EO-5093-516-004 PE
REGULATOR BLOCK
FLOW METERS SOL
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST)
SOL2 BW
FLUSH2
ESTCODE WASH LINE TO GUN

H1
SOL
SOL
HS1
PS1
PR1
SOL2
AIR
DUMP TO WASTE
RECLAIMATION

SOL SEE NOTE 1
NOTES:

EO5093-895-007H SHOWN
P2IP.
GUN OPTION CIRCULATING RESIN
INLET FLOW METERS
[EG-00413] REV B
FIXED REG.
-209-
WARNING
EO5093-895-007L SHOWN
GUN OPTION CIRCULATING RESIN WARNING
NON-CIRCULATING CATALYST before you perform any service or
FIXED PRESSURE REGULATORS you could injure personnel or damage
equipment.
INLET PRESSURE SENSORS
EE-4696
I.S. GROUND 6.9MM SEE EG-00010 FOR TORQUE SPECIFICATIONS
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
EE-5093-306-0XX
CASCADE
P
24V REV B AREA
PNEUMATICS COLUMN PURGED CARRIAGE EE-4696-272-002 CLASS 1
EE-5093-426-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR JOINT 3
HIGH VOLTAGE CBL
CBLEo000000365o
I/P MPPE 4-20mA FAN AIR CASCADE EE-4696-625-003 QD
Z787 P1IP RESIN INLET PRES

8 1
4-20mA 7 2 EE-4696-267-004
HONEYWELL P/I 4-20mA
6 G3
5 4
P1OP RESIN OUTLET PRES
8 1
7 2 EE-4696-267-004
6 G 3
5 4
P2OP CAT OUTLET PRES
8 1
7 2 EE-4696-267-004
6 G 3
X2 X1 5 4
X4 X3
AO2 8 1
EE-4696-267-004
P2IP CAT INLET PRES
6 G 3
X2 X1 5 4
X4 X3
AI4 CBLEo000000374o
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-426-001
8IN/8OUT
526257
CPX
MS
NS
IO
SF
PS
PL
M
COLOR VALVES
EE-5093-411-001

[EG-00413] REV B
FIXED REG.
-210-
WARNING
EO5093-895-007H SHOWN WARNING

GUN OPTION CIRCULATING RESIN Always disconnect power to the robot
EE-4696 SEE EG-00008 FOR LOCTITE REQUIREMENTS
171-00X EE-4696-171-00X SEE EG-00010 FOR TORQUE SPECIFICATIONS
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1 EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V REV B
I.S. GROUND
AREA
EE-4696-272-002 CLASS 1
PNEUMATICS COLUMN PURGED CARRIAGE
EE-5093-424-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR REF
HIGH VOLTAGE CBL
CBLEo000000365o
Z787 EE-5093-428-001 1K INLET FLOW
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
R R
SIG- 16 1K OUTLET PRES
8 G 1
7 2 EE-4696-267-004
HONEYWELL SENS
8 1
2K OUTLET PRES
SAME WIRE BARREL 7 G EE-4696-267-004
2
3 HONEYWELL SENS
6
5 4
X2 X1
X4 X3
AO2 24V 9 EE-5093-410 +V 6 8 G1
EE-5093-428-001
(AW CABLE/4/T/8 )
2K INLET FLOW
X2 X1 CBLEo000000374o SIG+ 14 FREQ. XDUCER Fin 3 5 4
X4 X3
AI4 P/I 4-20mA ATOMIZING AIR
SIG- 16 R R
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-424-001
8IN/8OUT JOINT 3
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
NOTES:
TO Z787 BARRIERS
[EG-00413] REV B
FIXED REG.
-211-
Figure 8-43 EG-00414 Sheet 1 of 4, P-700 GUN OPTION 2K 1+1 SCHEMATIC - VAR. REG.
WARNING
REG1 4mm
I/P G1/4 CPX/MPA - EO5093-110-001T SHOWN components. Otherwise you could
REG1 injure personnel or damge equipment
TDUCO000000004O MPA10-24
1 WARNING
PORT 82/84 MPA10-17 Always disconnect power to the robot
REG2 4mm SUPPLY PLATE maintenance procedures. Otherwise,
2 3
I/P G1/4 MPA10-16 you could injure personnel or damage
6 mm
REG2 PORT 1 equipment.
TDUCO000000004O MPA10-09
EO-5093-531-000
1 SEE EG-00008 FOR LOCTITE REQUIREMENTS
MPA10-01
6 mm
PORT 3/5 PORT 1
MPA10-24 - PLUGGED
MPA10-23 - PLUGGED
MPA10-22 - PLUGGED
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
MPA10-17 - pC1 4mm
PORT 1
SUPPLY PLATE
6 mm
MPA10-16 - PLUGGED
MPA10-15 - PLUGGED
CPX/MPA
MPA10-12 - PLUGGED
MPA10-11- PLUGGED
3X FITCO000001381O
THRU INNER ARM
PORT 10 mm
MPA10-08 - pCC 4mm
PORT 6 mm
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm

MPA10-02 - PLUGGED
6 mm
(TURB2)
10mm
6 mm
3 6 mm
ATOMIZING AIR
(TURB1) FLOW SENSOR 2 10 mm
10mm
I/P G1/4
SENSO000000471O ATOMIZING AIR 1 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
(SA1)
3
10mm
I/P G1/4
FAN AIR FAN AIR
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00414] REV C1
P-700 GUN OPTION 2K 1+1 SCHEMATIC - SHEET 1 OF 4
VAR. REG.
-212-
WARNING
CATALYST OUTLET PRESSURE (P2OP) components. Otherwise you could
SEE NOTE 1
WARNING
REG1
equipment.

PAINT LINE TO GUN
C1
CC RES
AIR
PUMP1
(RESIN)
EO-5093-516-004 PE
ESTCODE REGULATOR BLOCK
FLOW METERS SOL
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST)
SOL2 BW
FLUSH2
ESTCODE WASH LINE TO GUN

H1
SOL
SOL
HS1
PS1
PR1
SOL2
AIR
REG2
DUMP TO WASTE
RECLAIMATION

SOL SEE NOTE 1
NOTES:

PRESSURE SENSORS (EO-5093-516-006) IN SOME CONFIGURATIONS. THE INLET
SENSOR LABELS (P1IM & P2IM) ARE REPLACED WITH P1IP & P2IP.
EO5093-895-007J SHOWN
GUN OPTION CIRCULATING RESIN
INLET FLOW METERS
[EG-00414] REV C1
VAR. REG.
-213-
WARNING
EO5093-895-007M SHOWN WARNING

GUN OPTION CIRCULATING RESIN Always disconnect power to the robot
VARIABLE PRESSURE REGULATORS equipment.
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9 SEE EG-00010 FOR TORQUE SPECIFICATIONS
ETHERNET
SW MEDIA
FIBER CONV EE-5405-163-003
FIBER FIBER
COLUMN 1
EE-5093-406-001
EE-5093-301-0xx
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
24V EE-5151-014-001
DIAM. 14.7mm(0.58in) REV B AREA
HC-DD 24 I.S. GROUND
B6 HOUSING
EE-5093-426-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
JOINT 3
CBLEo000000365o
I/P MPPE 4-20mA FAN AIR REF
HIGH VOLTAGE CBL
CBLEo000000365o
I/P MPPE 4-20mA REGULATOR 2 CASCADE EE-4696-625-003 QD
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR Z787 P1IP RESIN INLET PRES
8 1
4-20mA 7 2 EE-4696-267-004
CBLEo000000365o HONEYWELL P/I 4-20mA
I/P MPPE 4-20mA REGULATOR 1 6 G3
5 4
8 1
7 2 EE-4696-267-004
6 G 3
5 4
X2 X1
X4 X3
AO2 8 1
EE-4696-267-004
6 G 3
X2 X1 5 4
X4 X3
AO2 8 1
EE-4696-267-004
P2IP CAT INLET PRES
6 G 3
X2 X1 5 4
X4 X3
AI4 CBLEo000000374o
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-426-001
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
[EG-00414] REV C1
VAR. REG.
-214-
WARNING
EO5093-895-007J SHOWN injure personnel or damge equipment
GUN OPTION CIRCULATING RESIN WARNING

NON-CIRCULATING CATALYST Always disconnect power to the robot
VARIABLE PRESSURE REGULATORS before you perform any service or
INLET FLOW METERS you could injure personnel or damage
equipment.
EE-4696
171-00X EE-4696-171-00X UNLESS OTHERWISE NOTED:
I.S. GROUND 6.9MM SEE EG-00008 FOR LOCTITE REQUIREMENTS
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
HAZARDOUS
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V AREA
EE-5093-424-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000365o
HIGH VOLTAGE CBL
CBLEo000000365o
CBLEo000000363o Z787
I/P MPPE 4-20mA ATOMIZING AIR EE-5093-428-001 P1IM 1K INLET FLOW
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
CBLEo000000365o 0V 10 PHOENIX 0V 4 7 2 AW FLOWMETER
I/P MPPE 4-20mA REGULATOR 1 SIG+ 14 FREQ. XDUCER Fin 3 5 4
R R
SIG- 16 P1OP 1K OUTLET PRES
8 1
7G 2 EE-4696-267-004
6 3 HONEYWELL SENS
5.1K Ohm RESISTORS
X2 X1 PUT LEADS & WIRES IN P2OP 2K OUTLET PRES
X4 X3
AO2 SAME WIRE BARREL 8 1
7G 2 EE-4696-267-004
6 3 HONEYWELL SENS
5 4
X2 X1
X4 X3
AO2 24V 9
EE-5093-410 +V 6 8 G1
EE-5093-428-001
(AW CABLE/4/T/8 )
P2IM 2K INLET FLOW
CBLEo000000374o SIG+ 14 FREQ. XDUCER Fin 3 5 4
X2 X1
AI4 SIG- 16 R R
X4 X3 P/I 4-20mA ATOMIZING AIR
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-424-001
JOINT 3
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
NOTES:
TO Z787 BARRIERS
NOTES
[EG-00414] REV C1
VAR. REG.
-215-
Figure 8-47 EG-00415 Sheet 1 of 4, GUN OPTION MULTIRESIN 2K SCHEMATIC - FIXED REG.
WARNING
CPX/MPA - EO5093-110-001AA SHOWN components. Otherwise you could
MPA10-48 WARNING
equipment.
PORT 82/84
24X FITCO000001381O
THRU INNER ARM WALL MPA10-25
SUPPLY PLATE UNLESS OTHERWISE NOTED:
PORT 1
MPA10-25 - pC1
EO-5093-531-000
THRU MPA10-16 MPA10-17

MPA10-48 - pC24
3X FITCO000001381O MPA10-09
THRU INNER ARM WALL SUPPLY PLATE
MPA10-24 - PLUGGED
MPA10-02
MPA10-23 - pH3 4mm
MPA10-01
MPA10-22 - pH2 4mm
MPA10-21 - pH1 4mm
MPA10-20 - pCAT 4mm

PORT 3/5 PORT 1
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
THRU INNER ARM
WALL
MPA10-16 - p2T 4mm
CPX/MPA
THRU AXIS 3
HOUSING
3X FITCO000001381O MPA10-11- PLUGGED

THRU INNER ARM
WALL
PORT
PORT
MPA10-07 - pAIR 4mm
EXHAUST MANIFOLD -
82/84
MPA10-06 - pSOL 4mm
FITMO000002095O
10 mm
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm

MPA10-02 - PLUGGED
(TURB2)
10mm
6 mm
3
ATOMIZING AIR 10 mm
(TURB1) FLOW SENSOR 2 I/P G1/4
ATOMIZING AIR 1
10mm 10 mm
SENSO000000471O
TDUCO000000004O EXHAUST TO
10 mm
BOOTH
6 mm
(SA1)
3
10mm
I/P G1/4
FAN AIR FAN AIR
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00415] REV B
GUN OPTION MULTIRESIN 2K SCHEMATIC SHEET 1 OF 4
- FIXED REG.
-216-
WARNING
CATALYST OUTLET PRESSURE (P2OP)SEE NOTE 1 EO-5093-516-011
WARNING
ESTCODE PAINT LINE TO GUN Always disconnect power to the robot
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO GUN

SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
PS2
PR2
RECLAIMATION
PR4
PS4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
NOTES:
PS1
PR1
PS21
PR21
PS23
PR23
PR3
PS3
2T
EO-5093-510-001
GUN OPTION (24) RESIN - CIRCULATING
INLET FLOW METERS
[EG-00415] REV B
- FIXED REG.
-217-
WARNING
EO5093-895-008AF SHOWN WARNING

GUN OPTION (24) RESIN - CIRCULATING Always disconnect power to the robot
EE-4696
I.S. GROUND 6.9MM SEE EG-00010 FOR TORQUE SPECIFICATIONS
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
EE-5093-306-0XX
CASCADE
P
24V REV B AREA
EE-5093-426-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR JOINT 3
HIGH VOLTAGE CBL
CBLEo000000365o
Z787 P1IP RESIN INLET PRES

8 1
4-20mA 7 2 EE-4696-267-004
6 G3
5 4
8 1
7 2 EE-4696-267-004
6 G 3
5 4
8 1
7 2 EE-4696-267-004
6 G 3
X2 X1 5 4
X4 X3
AO2 8 1
EE-4696-267-004
P2IP CAT INLET PRES
6 G 3
X2 X1 5 4
X4 X3
AI4 CBLEo000000374o
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-426-001
8IN/8OUT
526257
CPX
MS
NS
IO
SF
PS
PL
M
COLOR VALVES
EE-5093-411-001

[EG-00415] REV B
- FIXED REG.
-218-
WARNING
EO5093-895-008BT SHOWN injure personnel or damge equipment
GUN OPTION (24) RESIN - CIRCULATING WARNING

(3) CATALYST - CIRCULATING Always disconnect power to the robot
FIXED PRESSURE REGULATORS before you perform any service or
INLET FLOW METERS you could injure personnel or damage
equipment.

EE-4696 SEE EG-00008 FOR LOCTITE REQUIREMENTS
171-00X EE-4696-171-00X SEE EG-00010 FOR TORQUE SPECIFICATIONS
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1 EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V REV B
I.S. GROUND
AREA
EE-4696-272-002 CLASS 1
PNEUMATICS COLUMN PURGED CARRIAGE
EE-5093-424-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR REF
HIGH VOLTAGE CBL
CBLEo000000365o
Z787 EE-5093-428-001 1K INLET FLOW
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
R R
SIG- 16 1K OUTLET PRES
8 G 1
7 2 EE-4696-267-004
HONEYWELL SENS
8 1
2K OUTLET PRES
SAME WIRE BARREL 7 G EE-4696-267-004
2
3 HONEYWELL SENS
6
5 4
X2 X1
X4 X3
AO2 24V 9 EE-5093-410 +V 6 8 G1
EE-5093-428-001
(AW CABLE/4/T/8 )
2K INLET FLOW
X2 X1 CBLEo000000374o SIG+ 14 FREQ. XDUCER Fin 3 5 4
X4 X3
AI4 P/I 4-20mA ATOMIZING AIR
SIG- 16 R R
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-424-001
8IN/8OUT JOINT 3
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
NOTES:
TO Z787 BARRIERS
[EG-00415] REV B
- FIXED REG.
-219-
Figure 8-51 EG-00416 Sheet 1 of 4, GUN OPTION MULTIRESIN 2K SCHEMATIC - VAR. REG.
WARNING
REG1 4mm I/P G1/4 3 CPX/MPA - EO5093-110-001X SHOWN procedures when you install or remove
2
TDUCO000000004O injure personnel or damge equipment
6 mm
FITCO000001381O REG1
MPA10-48
THRU INNER ARM WALL 1 WARNING
2 I/P G1/4 3 before you perform any service or
REG2 4mm maintenance procedures. Otherwise,
TDUCO000000004O you could injure personnel or damage
PORT 82/84 equipment.
REG2 MPA10-25
24X FITCO000001381O 1
THRU INNER ARM WALL SUPPLY PLATE UNLESS OTHERWISE NOTED:
EO-5093-531-000
PORT 1 SEE EG-00010 FOR TORQUE SPECIFICATIONS
6 mm
MPA10-16 MPA10-17
MPA10-25 - pC1
THRU
MPA10-48 - pC24
6 mm
MPA10-09
3X FITCO000001381O
PORT 1
THRU INNER ARM WALL SUPPLY PLATE MPA10-02
6 mm
MPA10-24 - PLUGGED MPA10-01
MPA10-23 - pH3 4mm
MPA10-22 - pH2 4mm
MPA10-21 - pH1 4mm

PORT 3/5 PORT 1
MPA10-20 - pCAT 4mm
MPA10-19 - pRES 4mm
MPA10-18 - PLUGGED
THRU INNER ARM
WALL
MPA10-16 - p2T 4mm
CPX/MPA
THRU AXIS 3
HOUSING
3X FITCO000001381O MPA10-11 - PLUGGED

THRU INNER ARM
WALL
PORT
PORT
EXHAUST MANIFOLD -
MPA10-07 - pAIR 4mm
82/84
MPA10-06 - pSOL 4mm
10 mm
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm

MPA10-02 - PLUGGED
(TURB2)
10mm 6 mm
6 mm
3
ATOMIZING AIR 10 mm
ATOMIZING AIR 1
10mm 10 mm
SENSO000000471O
TDUCO000000004O
6 mm 10 mm
(SA1)
3
10mm EXHAUST TO
I/P G1/4 BOOTH
FAN AIR FAN AIR
SENSO000000471O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
CARRIAGE AIR
[EG-00416] REV B
- VAR. REG.
-220-
WARNING
WARNING
ESTCODE PAINT LINE TO GUN Always disconnect power to the robot
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO GUN

REG2
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
REG
PS2
PR2
RECLAIMATION
PR4
PS4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
2T
NOTES:

PS1
PR1
PS21
PR21
PS23
PR23
PR3
PS3

2T
EO-5093-510-001
GUN OPTION (24) RESIN - CIRCULATING
INLET FLOW METERS
[EG-00416] REV B
- VAR. REG.
-221-
WARNING
EO5093-895-008F SHOWN WARNING

GUN OPTION (24) RESIN - CIRCULATING Always disconnect power to the robot
VARIABLE PRESSURE REGULATORS equipment.
EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9 SEE EG-00010 FOR TORQUE SPECIFICATIONS
ETHERNET
SW MEDIA
FIBER CONV EE-5405-163-003
FIBER FIBER
COLUMN 1
EE-5093-406-001
EE-5093-301-0xx
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
ESTAT
CONTROL
P HH
24V EE-5151-014-001
DIAM. 14.7mm(0.58in) REV B AREA
HC-DD 24 I.S. GROUND
B6 HOUSING
EE-5093-426-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
JOINT 3
CBLEo000000365o
HIGH VOLTAGE CBL
CBLEo000000365o
CBLEo000000363o
I/P MPPE 4-20mA ATOMIZING AIR Z787 P1IP RESIN INLET PRES
8 1
4-20mA 7 2 EE-4696-267-004
CBLEo000000365o HONEYWELL P/I 4-20mA
I/P MPPE 4-20mA REGULATOR 1 6 G3
5 4
8 1
7 2 EE-4696-267-004
6 G 3
5 4
X2 X1
X4 X3
AO2 8 1
EE-4696-267-004
6 G 3
X2 X1 5 4
X4 X3
AO2 8 1
EE-4696-267-004
P2IP CAT INLET PRES
6 G 3
X2 X1 5 4
X4 X3
AI4 CBLEo000000374o
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-426-001
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
[EG-00416] REV B
- VAR. REG.
-222-
WARNING
EO5093-895-008AT SHOWN
GUN OPTION (24) RESIN - CIRCULATING WARNING
(3) CATALYST - CIRCULATING before you perform any service or
VARIABLE PRESSURE REGULATORS you could injure personnel or damage
INLET FLOW METERS equipment.
EE-4696
171-00X EE-4696-171-00X UNLESS OTHERWISE NOTED:
I.S. GROUND 6.9MM SEE EG-00008 FOR LOCTITE REQUIREMENTS
PG9
ETHERNET
SW MEDIA
FIBER CONV
COLUMN 1
EE-5093-401-001
EE-5093-301-0xx
P
JOINT 1 JOINT 2
EE-5093-206-0XX
EE-5093-306-0XX
SEAL
EE-5093-106-00X
HAZARDOUS
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V AREA
EE-5093-424-001 GROUP C,E,E,F
EE-5093-426-001
CBLEo000000374o
P/I 4-20mA FAN AIR
CBLEo000000365o
HIGH VOLTAGE CBL
CBLEo000000365o
CBLEo000000363o Z787
I/P MPPE 4-20mA ATOMIZING AIR EE-5093-428-001 P1IM 1K INLET FLOW
24V 9 EE-5093-410 +V 6 8 G1 (AW CABLE/4/T/8 )
CBLEo000000365o 0V 10 PHOENIX 0V 4 7 2 AW FLOWMETER
I/P MPPE 4-20mA REGULATOR 1 SIG+ 14 FREQ. XDUCER Fin 3 5 4
R R
SIG- 16 P1OP 1K OUTLET PRES
8 1
7G 2 EE-4696-267-004
6 3 HONEYWELL SENS
5.1K Ohm RESISTORS
X2 X1 PUT LEADS & WIRES IN P2OP 2K OUTLET PRES
X4 X3
AO2 SAME WIRE BARREL 8 1
7G 2 EE-4696-267-004
6 3 HONEYWELL SENS
5 4
X2 X1
X4 X3
AO2 24V 9
EE-5093-410 +V 6 8 G1
EE-5093-428-001
(AW CABLE/4/T/8 )
P2IM 2K INLET FLOW
CBLEo000000374o SIG+ 14 FREQ. XDUCER Fin 3 5 4
X2 X1
AI4 SIG- 16 R R
X4 X3 P/I 4-20mA ATOMIZING AIR
EE-5093-426-001
X2 X1
X4 X3
AI4 EE-5093-424-001
JOINT 3
8IN/8OUT
526257
CPX
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
EE-5093-411-001
NOTES:
TO Z787 BARRIERS
NOTES
[EG-00416] REV B
- VAR. REG.
-223-
Figure 8-55 EG-00440 Sheet 1 of 3, P-700 SMC 1K WITH REG SCHEMATICS
WARNING
6 mm extreme care and follow proper lifting
REG1 4mm
2 3 S07-40 S07-39 procedures when you install or remove
FITCO000001381O (TYP) - I/P components. Otherwise you could
THROUGH INNER ARM WALL REG 1 injure personnel or damge equipment
TDUCO000000020O
S07-40 - pC24 4mm
S07-39 - pC23 4mm 1 WARNING
REMOTE
S07-38 - pC22 4mm S07-34 S07-33 Always disconnect power to the robot
EX600
S07-37 - pC21 4mm before you perform any service or
S07V-36 - pC20 4mm
PORT 3/5 PORT 1 you could injure personnel or damage
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
6 mm
E 3/5 PORT 1 PORT 3/5 SEE EG-00008 FOR LOCTITE REQUIREMENTS
PLUGGED PLUGGED SEE EG-00010 FOR TORQUE SPECIFICATIONS
SV-32 - pC16 4mm
P1
SV-31 - pC15 4mm PLUGGED
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-25 - pC9 4mm 8 mm TEE
SV-24 - pC8 4mm FITTING
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-21 - pC5 4mm 8 mm 8 mm
SV-01
SV-19 - pC3 4mm 8 mm
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - p2T 4mm
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-14 - PLUGGED 8 mm
SV-13 - pVENT 4mm E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
SV-05 - pBW 4mm 8 mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH
SA1 10mm 3 12mm SHAPE AIR

I/P
2 SHAPE AIR 1 FLOW SENSOR
SA2 10mm TDUCO000000019O 12mm HPNMO000019117O
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 12MM
SENSO000000473O
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00440] REV B
P-700 SMC 1K WITH REG SCHEMATICS SHEET 1 OF 3
-224-
WARNING
WARNING
SOL
DUMP2
RECOVERY
REG RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
pIW
INJECTOR
P/I
pAIR pBW
p2T
BELL WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00440] REV B
-225-
WARNING
WARNING
equipment.

OUTSIDE PAINT BOOTH SEE EG-00010 FOR TORQUE SPECIFICATIONS
INSIDE PAINT BOOTH
ROBOT CONTROLLER PANEL (ACP)
EE-6246-207-XXX
LOW VOLTAGE CABLE
ESTAT EE-6246-107-XXX
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-179-XXX CONV
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
PURGED UNPURGED HAZARDOUS
AREA
CLASS 1
24V DIVISION 1
PROCESS EE-6246-105-XXX GROUP C,D,E,F
POWER
24V POWER
EE-4696-272-002
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-003 QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
CABLE INCLUDED ON EE-4696-021 EE-4696-021 DUAL FIBER - EE-4560-655-002 DUAL FIBER - EE-4560-654-003
KEYENCE
CBLEO000000385O
I/P ITV 4-20mA TURBINE DRIVE
CBLEO000000386O REGULATOR
I/P ITV 4-20mA
CBLEO000000384O
I/P ITV 4-20mA SHAPE AIR 1
CBLEO000000388O
Q/I 4-20mA SHAPE AIR 1 FLOW SENSOR
CABLE AND SENSOR - SENSO000000473O P/I BEARING AIR

4-20mA
SMC EX600 PROCESS I/O

ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1
ST PWR PWRV MS NS
0 1 0 1 0 1
2 3 2 3 2 3 SET T ING 1 SET T ING 2
COLOR VALVES
SET T ING 3 COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00440] REV B
-226-
Figure 8-58 EG-00441 Sheet 1 of 3, P-700 SMC 1K FIXED REG SCHEMATICS
WARNING
S07-40 S07-39 procedures when you install or remove
THROUGH INNER ARM WALL injure personnel or damge equipment
S07-40 - pC24 4mm

S07-39 - pC23 4mm WARNING
REMOTE
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
PLUGGED
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-01
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - p2T 4mm
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 12MM
SENSO000000473O
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00441] REV B
P-700 SMC 1K FIXED REG SCHEMATICS SHEET 1 OF 3
-227-
WARNING
WARNING
SOL
DUMP2
RECOVERY
RECOVERY
pC4 pC2
pDUMP PAINT
FIXED pTRIG SEE EG-00010 FOR TORQUE SPECIFICATIONS
pSOL
REGULATOR
15 PSI OR pIW
30 PSI INJECTOR
P/I
pAIR pBW
p2T
BELL WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00441] REV B
-228-
WARNING
WARNING
equipment.

OUTSIDE PAINT BOOTH INSIDE PAINT BOOTH SEE EG-00010 FOR TORQUE SPECIFICATIONS
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-4696-272-002
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-003 QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
CBLEO000000384O
CBLEO000000388O
CABLE AND SENSOR - SENSO000000473O P/I 4-20mA BEARING AIR

ST PWR P WRV MS NS
0 1 0 1 0 1
COLOR VALVES
COLOR VALVES
SE T T ING 3
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00441] REV B
-229-
Figure 8-61 EG-00442 Sheet 1 of 4, 1K SMC WITH REG SCHEMATICS
WARNING
REG1 4mm
ITV 1050-04F2
3 procedures when you install or remove
FITCO000001381O (TYP) - 2 components. Otherwise you could
THROUGH CARRIAGE injure personnel or damge equipment
1
REG 1 6 mm
S07-40 - pC24 4mm SMC EX600
S07-39 - pC23 4mm E06246-110-002C SHOWN WARNING
6 mm
S07-38 - pC22 4mm EO6246-110-003A SHOWN Always disconnect power to the robot
Plug before you perform any service or
S07-37 - pC21 4mm SMC EX600 Plug
S07-36 - pC20 4mm REMOTE SV-31 S07-40 maintenance procedures. Otherwise,
8mm EXH SV-32 (pc24) S07-39 you could injure personnel or damage
S07-35 - pC19 4mm
PORT 3 (pc16) (pc15)
(pc23) equipment.
S07-34 - pC18 4mm S07-34
PORT 1
S07-33 - pC17 4mm (pc18) S07-33
REMOTE SUPPLY (pc17) UNLESS OTHERWISE NOTED:
8 MM
6 mm
Supply SEE EG-00010 FOR TORQUE SPECIFICATIONS
SV-12 (8 mm)
SV-32 - pC16 4mm SV-11
(pDump2) Exhaust
SV-31 - pC15 4mm (Seal)
SV-02 (8 mm)
SV-30 - pC14 4mm
SV-29 - pC13 4mm
(Brake)
SV-01
SV-28 - pC12 4mm Supply (pTrig)
SV-27 - pC11 4mm (8 mm)
Exhaust
SV-26 - pC10 4mm (8 mm)
SV-25 - pC9 4mm
SV-24 - pC8 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm
SV-21 - pC5 4mm
SV-20 - pC4 4mm

SV-19 - pC3 4mm
SV-18 - pC2 4mm SMC EX600
SV-17 - pC1 4mm LOCAL
SV-16 - PLUGGED
SV-15 - PLUGGED
SV-14 - PLUGGED
SV-13 - PLUGGED
SV-12 - pDUMP2 4mm
SV-11- SEAL 6mm
SV-10 - pFLUSH 4mm 8mm EXH

PORT
SV-09 - pDUMP 4mm 3/5
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
LOCAL SUPPLY
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm 8 MM
SV-05 - pBW 4mm PORT 1
FITMO000002095O
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
6 mm
10 mm
EXHAUST TO
6 mm BOOTH
3
TURB2 10mm TBSP1 - 12MM
TURB1 10mm
2 ITV 2050-04F3N4-X69 1
TBSP2 - 12MM
Turbine Air
CARRIAGE ROX
SA2 10mm PROCESS AIR SUPPLY 2 - 12mm
3
SA1 10mm FLOWMETER
ITV 2050-04F3N4-X69 PF2A551-F04-2
1 PROCESS AIR SUPPLY 1 - 12mm
2
BEARING AIR SENSE Shape Air
PSE540
BEAR 6mm BEAR 8mm
[EG-00442] REV C
1K SMC WITH REG SCHEMATICS SHEET 1 OF 4
-230-
WARNING
WARNING
DUMP
SOL
REG RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00442] REV C
-231-
WARNING
P500iA R30iA 1K WARNING

equipment.


AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
EE-6102-276-XXX
LOW VOLTAGE CABLE
24V POWER EE-4696-272-002
I.S. GROUND
EE-6102-161-0XX
ETHERNET
JOINT 2,3
CASCADE
REF- EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787
REF 1K PRES
EE-5093-426-001 4-20mA 8 1 EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
CABLE INCLUDED ON EE-4696-021 EE-4696-021 REF - EE-4560-655-001 REF - EE-4560-654-00X
KEYENCE DUAL FIBER DUAL FIBER
CBLEO000000384O TURBINE DRIVE
I/P ITV 4-20mA
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000388O

1-5V
SMC EX600 PROCESS I/O SEE TABLES FOR DIP SWITCH SETTINGS NOTE 3: SET SETTINGS 3 SWITCHES EQUAL TO SETTING LISTED IN ABOVE TABLE
ST P WR P WRV MS NS
0 1 0 1 0 1
2 3 2 3 2 3 SET T ING 1 S ET T ING 2
COLOR VALVES
COLOR VALVES
CC VALVES
D-SUB 25 PIN
CC VALVES
S ET T ING 3
IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
NOTE 4: SET SWTICHES NO 1 AND NO 2 ACCORDING TO NUMBER

CBLEO000000387O OF SOLENOIDS CONNECTED TO LOCAL VALVE STACK.
COUNT NUMBER OF VALVES

FOR USE IN SETUP FOR
SETTINGS 3, SWITCH NO 1
AND NO 2.
(2 VALVES PER SLICE)
NOTE 1: SET SETTINGS 1 SWITCHES EQUAL TO SETTING LISTED IN ABOVE TABLE
NOTE 2: SET IP ADDRESS NUMBER IN SETTINGS 2 TABLE EQUAL TO ROBOT NUMBER IN ZONE
[EG-00442] REV C
-232-
WARNING
P500iA FLEX 1K components. Otherwise you could
WARNING
PURGED UNPURGED HAZARDOUS maintenance procedures. Otherwise,
AREA you could injure personnel or damage
equipment.
CLASS 1
DIVISION 1 UNLESS OTHERWISE NOTED:
GROUP C,D,E,F SEE EG-00008 FOR LOCTITE REQUIREMENTS
REF- EE-6246-207-XXX
LOW VOLTAGE CABLE
24V POWER EE-4696-272-002
I.S. GROUND
EE-6102-161-0XX
ETHERNET
JOINT 2,3 REF-
EE-4696-625-00X QD
CASCADE
HIGH VOLTAGE CABLE
Z787 REF 1K PRES

EE-5093-426-001 8 1 EE-4696-267-002
4-20mA
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000388O

1-5V
SMC EX600 PROCESS I/O SEE TABLES FOR DIP SWITCH SETTINGS
ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 SEE EG-00454 FOR DIP SW SETUP
ST PWR PW RV MS NS
0 1 0 1 0 1
3 2 3 2 3
COLOR VALVES
2
COLOR VALVES
SE T T ING 1 SE T T ING 2
VALVES
VALVES
D-SUB 25 PIN
S ET T ING 3
IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
CC
CC
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O

AND NO 2.
SEE EG-00454 FOR DIP SW
SETUP.
[EG-00442] REV C
-233-
Figure 8-65 EG-00443 Sheet 1 of 3, P-500iA 1K WITH REG SCHEMATICS
WARNING
REG1 4mm 3 procedures when you install or remove
ITV 1050-04F2
FITCO000001381O (TYP) - 2 components. Otherwise you could
THROUGH CARRIAGE injure personnel or damage equipment
1
REG 1 6 mm
S07-40 - pC24 4mm
6 mm
S07-38 - pC22 4mm Always disconnect power to the robot
S07-37 - pC21 4mm SMC EX600 before you perform any service or
S07-36 - pC20 4mm REMOTE maintenance procedures. Otherwise,
8mm EXH
SMC EX600 you could injure personnel or damage
S07-35 - pC19 4mm
PORT 3 E06246-110-002C SHOWN equipment.
S07-34 - pC18 4mm
PORT 1
S07-33 - pC17 4mm
Plug
REMOTE SUPPLY Plug UNLESS OTHERWISE NOTED:
8 MM SV-31
SV-32 SEE EG-00008 FOR LOCTITE REQUIREMENTS
6 mm
(pc16) (pc15) SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO6246-110-003A SHOWN
SV-32 - pC16 4mm
SV-31 - pC15 4mm
SV-30 - pC14 4mm
S07-40
SV-29 - pC13 4mm (pc24) S07-39
SV-28 - pC12 4mm SV-12 S07-34 (pc23)
SV-11
SV-27 - pC11 4mm (pDump2) (pc18) S07-33
(Seal)
SV-26 - pC10 4mm SV-02 (pc17)
SV-25 - pC9 4mm (Brake)
SV-24 - pC8 4mm SV-01 Supply
Supply (pTrig) (8 mm)
SV-23 - pC7 4mm
(8 mm) Exhaust
SV-22 - pC6 4mm Exhaust
(8 mm) (8 mm)
SV-21 - pC5 4mm
SV-20 - pC4 4mm

SV-19 - pC3 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
SV-14 - PLUGGED
SV-13 - PLUGGED
SV-12 - pDUMP2 4mm
SV-11- SEAL 6mm

PORT
SV-08 - pCC 4mm
SV-07 - pAIR 4mm LOCAL SUPPLY
8 MM
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002095O
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
6 mm
10 mm
6 mm EXHAUST TO
6 mm BOOTH
3
TURB1 10mm
2 ITV 2050-04F3N4-X69 1
TBSP2 - 12MM
Turbine Air
CARRIAGE ROX
3 Shape Air
PROCESS AIR SUPPLY 2 - 12mm
SA2 10mm 2
ITV 2050-04F3N4-X69 FLOWMETER
PF2A551-F04-2
1 3
SA1 10mm FLOWMETER
ITV 2050-04F3N4-X69 PF2A551-F04-2
2 1 PROCESS AIR SUPPLY 1 - 12mm
PSE540
BEAR 6mm BEAR 8mm
[EG-00443] REV A
P-500iA 1K WITH REG SCHEMATICS SHEET 1 OF 3
ITV 2050-04F3N4-X69
-234-
WARNING
WARNING
DUMP
SOL
REG RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00443] REV A
-235-
WARNING
LOW VOLTAGE CABLE procedures when you install or remove
WARNING
I.S. GROUND
KEYENCE
EE-4696-020
UNPURGED Always disconnect power to the robot
PURGED TURBINE ITV
2050-04F3N4-X69
equipment.
4-20 mA out
Z787 BARRIER
HAZARDOUS UNLESS OTHERWISE NOTED:
24V POWER
P10P
REGULATOR 1
AREA SEE EG-00008 FOR LOCTITE REQUIREMENTS
ITV 1050-04F2
4-20 mA out
HIGH VOLTAGE CBL
BEARING AIR SENSE EE-4696-625-00X
ETHERNET PSE540
4-20 mA in EE-4560-653-00x
SHAPE AIR 2 ITV
2050-04F3N4-X69 CASCADE
QD
4-20 mA out
SHAPE AIR FLOWMETER 2

PF2A551-F04-2
4-20 mA in 1K PRESSURE
J2, J3
SENSOR
SHAPE AIR 1 ITV
2050-04F3N4-X69 HONEYWELL P/I
4-20 mA out
SHAPE AIR FLOWMETER 1 Dual EE-4560-654-00X (REF)

PF2A551-F04-2
4-20 mA in Fiber
Color Valves 17-32 Process Valves 01-16
Analog out
3 2 3 2 3 2
1
1 0 1 0 0
Analog in
SMC EX600 Counter MOD2 MOD1
Color Valves 33-40
[EG-00443] REV A
-236-
Figure 8-68 EG-00444 Sheet 1 of 4, 1K SMC FIXED REG SCHEMATICS
WARNING
4 mm (plugged @ elbow when fluid reg not used) extreme care and follow proper lifting
S07-40 - pC24 4mm SMC EX600

S07-35 - pC19 4mm
(pc23) equipment.
S07-34 - pC18 4mm S07-34
PORT 1
S07-33 - pC17 4mm (pc18) S07-33
8 MM
SV-12 (8 mm)
SV-32 - pC16 4mm SV-11
(pDump2) Exhaust
SV-02 (8 mm)
SV-30 - pC14 4mm
SV-29 - pC13 4mm
(Brake)
SV-01
SV-27 - pC11 4mm (8 mm)
Exhaust
SV-26 - pC10 4mm (8 mm)
SV-25 - pC9 4mm
SV-24 - pC8 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm
SV-21 - pC5 4mm
SV-20 - pC4 4mm

SV-19 - pC3 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
SV-14 - PLUGGED
SV-13 - PLUGGED
SV-12 - pDUMP2 4mm
SV-11- SEAL 6mm

PORT
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
LOCAL SUPPLY
EXHAUST MANIFOLD -
FITMO000002095O
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
6 mm
10 mm
EXHAUST TO
6 mm BOOTH
3
TURB1 10mm
2 ITV 2050-04F3N4-X69 1
TBSP2 - 12MM
Turbine Air
CARRIAGE ROX
3
SA1 10mm FLOWMETER
ITV 2050-04F3N4-X69 PF2A551-F04-2
2
PSE540
BEAR 6mm BEAR 8mm
[EG-00444] REV C
1K SMC FIXED REG SCHEMATICS SHEET 1 OF 4
-237-
WARNING
WARNING
DUMP
SOL
RECOVERY
pC4 pC2
pDUMP PAINT
pSOL
pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00444] REV C
-238-
WARNING
WARNING
P500iA R30iA 1K Always disconnect power to the robot
equipment.


AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
EE-6102-276-XXX
LOW VOLTAGE CABLE
24V POWER EE-4696-272-002
I.S. GROUND
EE-6102-161-0XX
ETHERNET
JOINT 2,3
CASCADE
REF- EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787 REF 1K PRES

EE-5093-426-001 4-20mA 8 1 EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000388O
CABLE AND SENSOR - SENSO000000473O P/I 1-5V BEARING AIR
SMC EX600 PROCESS I/O SEE TABLES FOR DIP SWITCH SETTINGS NOTE 3: SET SETTINGS 3 SWITCHES EQUAL TO SETTING LISTED IN ABOVE TABLE
ST PWR PW RV MS NS
0 1 0 1 0 1
2 3 2 3 2 3 SE T T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
CC VALVES
D-SUB 25 PIN
CC VALVES
SET T ING 3
IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
NOTE 4: SET SWTICHES NO 1 AND NO 2 ACCORDING TO NUMBER

CBLEO000000387O OF SOLENOIDS CONNECTED TO LOCAL VALVE STACK.

AND NO 2.
NOTE 1: SET SETTINGS 1 SWITCHES EQUAL TO SETTING LISTED IN ABOVE TABLE
NOTE 2: SET IP ADDRESS NUMBER IN SETTINGS 2 TABLE EQUAL TO ROBOT NUMBER IN ZONE
[EG-00444] REV C
-239-
WARNING
P500iA FLEX 1K injure personnel or damge equipment
WARNING
PURGED UNPURGED HAZARDOUS equipment.
AREA
CLASS 1 UNLESS OTHERWISE NOTED:
DIVISION 1 SEE EG-00010 FOR TORQUE SPECIFICATIONS
GROUP C,D,E,F
LOW VOLTAGE CABLE
24V POWER EE-4696-272-002
I.S. GROUND
EE-6102-161-0XX
ETHERNET
JOINT 2,3 REF-
EE-4696-625-00X QD
CASCADE
HIGH VOLTAGE CABLE
Z787 REF 1K PRES

EE-5093-426-001 8 1 EE-4696-267-002
4-20mA
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
CBLEO000000384O
CBLEO000000388O

1-5V
SMC EX600 PROCESS I/O SEE TABLES FOR DIP SWITCH SETTINGS
ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 SEE EG-00454 FOR DIP SW SETUP
ST PW R PW RV MS NS
0 1 0 1 0 1
3 2 3 2 3
COLOR VALVES
2
COLOR VALVES
S ET T ING 1 S ET T ING 2
VALVES
VALVES
D-SUB 25 PIN
SET T ING 3
IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
CC
CC
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O

AND NO 2.
SEE EG-00454 FOR DIP SW
SETUP.
[EG-00444] REV C
-240-
Figure 8-72 EG-00448 Sheet 1 of 3, P-700 SMC DUAL SHAPE AIR 1K WITH REG SCHEMATICS
WARNING
REG1 4mm
2 3 MPA10-40 MPA10-39 procedures when you install or remove
FITCO000001381O (TYP) - I/P components. Otherwise you could
THROUGH INNER ARM WALL REG 1 injure personnel or damge equipment
TDUCO000000020O
S07-40 - pC24 4mm
REMOTE
S07-38 - pC22 4mm MPA10-34 MPA10-33 Always disconnect power to the robot
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
6 mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 MPA10-32 MPA10-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm MPA10-02
MPA10-01
SV-20 - pC4 4mm
FITTING
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - p2T 4mm
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm 6 mm
6 mm
3
I/P 6 mm
2 TURBINE
TDUCO000000019O
TURB1 10mm 1
6 mm
10 mm
3 EXHAUST TO
I/P 10mm SHAPE AIR
SA1 10mm
2 SHAPE AIR 1 FLOW SENSOR 6 mm BOOTH
TDUCO000000019O HPNMO000019116O
CPX - 10MM
SUPPLY MANIFOLD
3
EO-5093-170-025
SA2 10mm I/P 10mm SHAPE AIR
CARRIAGE AIR
TDUCO000000019O HPNMO000019116O TBSP1 - 10MM
TBSP2 - 10MM
SHAPE AIR 1 - 12MM

BEAR 6mm
SHAPE AIR 2 - 12MM
BEAR 8mm
BEAR P/I
SENSO000000473O
[EG-00448]
P-700 SMC DUAL SHAPE AIR 1K WITH REV C
REG SCHEMATICS SHEET 1 OF 3
-241-
WARNING
WARNING
SOL
DUMP2
RECOVERY
REG RECOVERY
pC4 pC2
pDUMP PAINT
pTRIG
pSOL
pIW
INJECTOR
P/I
pAIR pBW
p2T
BELL WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00448]
-242-
WARNING
WARNING
equipment.

OUTSIDE PAINT BOOTH INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-4696-272-002
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-003 QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000384O
CBLEO000000388O
CBLEO000000388O

ST PWR PWRV MS NS
0 1 0 1 0 1
COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00448]
-243-
Figure 8-75 EG-00449 Sheet 1 of 3, P-700 SMC DUAL SHAPE AIR 1K FIX REG SCHEMATICS
WARNING
MPA10-40 MPA10-39 procedures when you install or remove
THROUGH INNER ARM WALL injure personnel or damge equipment
S07-40 - pC24 4mm

REMOTE
S07-38 - pC22 4mm MPA10-34 MPA10-33 Always disconnect power to the robot
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
PLUGGED
SV-29 - pC13 4mm
E 3/5 MPA10-32 MPA10-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm MPA10-02
MPA10-01
SV-20 - pC4 4mm
FITTING
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - p2T 4mm
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm 6 mm
6 mm
3
I/P
2 TURBINE
TDUCO000000019O
TURB1 10mm 1
6 mm
10 mm
3 EXHAUST TO
I/P 12mm SHAPE AIR
SA1 10mm
2 SHAPE AIR 1 FLOW SENSOR 6 mm BOOTH
TDUCO000000019O HPNMO000019116O
CPX - 10MM
SUPPLY MANIFOLD
3
EO-5093-170-025
SA2 10mm I/P 12mm SHAPE AIR
CARRIAGE AIR
TDUCO000000019O HPNMO000019116O TBSP1 - 10MM
TBSP2 - 10MM
SHAPE AIR 1 - 12MM

BEAR 6mm
SHAPE AIR 2 - 12MM
BEAR 8mm
BEAR P/I
SENSO000000473O
[EG-00449]
P-700 SMC DUAL SHAPE AIR 1K FIX REG REV B
SCHEMATICS SHEET 1 OF 3
-244-
WARNING
WARNING
equipment.

DUMP2 DUMP
SOL PS4 PR4 RECOVERY RECOVERY
PS2 PR2
pC4 pC2
pDUMP PAINT
SOLV/AIR pDUMP2 PAINT ENABLE
pPE
FIXED pTRIG
pSOL
REGULATOR
15 PSI OR pIW
30 PSI INJECTOR
P/I
pAIR pBW
p2T
BELL WASH
2T
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00449]
-245-
WARNING
WARNING
equipment.

EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-4696-272-002
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-003 QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
CBLEO000000384O
CBLEO000000384O
CBLEO000000388O
CBLEO000000388O

ST PWR P WRV MS NS
0 1 0 1 0 1
COLOR VALVES
COLOR VALVES
SE T T ING 3
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00449]
-246-
Figure 8-78 EG-00457 Sheet 1 of 4, P-700 SMC 2K 1+1 FIX REG SCHEMATIC
WARNING
WARNING
PORT 1 PORT 3/5 equipment.
PLUGGED PLUGGED
SV-24 SV-23 UNLESS OTHERWISE NOTED:
SV-02
SV-01
SV-24 - PLUGG ED P1
SV-23 - PLUGG ED
PLUGGED
SV-22 - PLUGG ED
E 3/5 PORT 1 PORT 3/5
SV-21 - pH1 4mm PLUGGED
SV-20 - pCAT 4mm FITTING
SV-19 - pRES 4mm 8 mm
EX600 LOCAL
SV-18 - PLUGG ED
SV-17 - pC1 4mm
SV-16 - PLUGG ED
SV-15 - PLUGG ED
10 mm
SV-14 - pFLUSH2 4mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - PLUGG ED
SV-11 - SEAL 6mm
FITCO000001381O
THRU INNER ARM SV-10 - pFLUSH 4mm
WALL SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096 O
SV-05 - pBW 4mm P1 8 mm
FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019 O
TURB1 10mm
1
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
SA2 10mm TDUCO000000019 O 10mm HPNMO000019117 O
SUPPLY MANIFOLD
CPX - 10MM
EO-6246-170-006
CARRIAGE AIR
BEAR 6mm
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 10MM
SENSO000000473O
SHAPE AIR 2 - 10MM
BEAR 8mm
[EG-00457] REV A
P-700 SMC 2K 1+1 FIX REG SCHEMATIC SHEET 1 OF 4
-247-
WARNING
SEE NOTE 1 WARNING
equipment.

PAINT LINE TO BELL
C1
CC RES
AIR
PUMP1
(RESIN)
EO-5093-516-004 PE
REGULATOR BLOCK
FLOW METERS SOL
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST)
SOL2 BW
FLUSH2

H1
SOL
SOL
HS1
PS1
PR1
SOL2
AIR
DUMP TO WASTE
RECLAIMATION

SOL SEE NOTE 1
NOTES:

EO6246-895-003H SHOWN
P2IP.
CIRCULATING RESIN
INLET FLOW METERS
[EG-00457] REV A
-248-
WARNING
2K 1+1 FIX REG WITH INLET PRESSURE SENSORS
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
CASCADE
EE-4696-625-003 QD
EE-4696-272-002 HIGH VOLTAGE CABLE
I.S. GROUND
JOINT 3
CABLE INCLUDED ON EE-4696-021 EE-4696-021 DUAL FIBER EE-4560-655-002 DUAL FIBER EE-4560-654-003
KEYENCE
Z787
TURBINE DRIVE 8 1 EE-4696-267-004
P2IP
CBLEO000000385O EE-5093-426-001 4-20mA
I/P ITV 4-20mA 7G 2 HONEYWELL I/P
5 4
Z787 P1OP
EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
7G 2 HONEYWELL I/P
5 4
SHAPE AIR 1 REG Z787 P2OP
EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
CBLEO000000384O I/P ITV 4-20mA 7G 2 HONEYWELL I/P
5 4
SHAPE AIR 1 FLOW SENSOR Z787 P1IP
EE-5093-426-001 4-20mA 8 1
CBLEO000000388O Q/I 4-20mA EE-4696-267-004
7G 2 HONEYWELL I/P
5 4
CABLE AND SENSOR

BEARING AIR
SENSO000000473O P/I 4-20mA
ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN S1

ST PWR PWRV MS NS
0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 SET T ING 1 SET T ING 2
COLOR VALVES

IN IN IN LOW SPEED
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI
OUT OUT OUT HIGH SPEED
[EG-00457] REV A
-249-
WARNING
2K 1+1 FIX REG WITH INLET FLOW SENSORS
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
CASCADE
EE-4696-625-003 QD
I.S. GROUND
JOINT 3
KEYENCE
Z787
P2OP
CBLEO000000385O EE-5093-426-001 4-20mA
5 4
Z787 P1OP
EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
7G 2 HONEYWELL I/P
5 4
SHAPE AIR 1 REG Z787 P1IM
EE-5093-424-001 4-20mA 8 1
CBLEO000000384O I/P ITV 4-20mA 7G 2
EE-5093-428-001 AW FLOWMETER
(AW CABLE/4/T/8
5 4
SHAPE AIR 1 FLOW SENSOR Z787 P2IM
EE-5093-424-001 4-20mA 8 1
CBLEO000000388O Q/I 4-20mA EE-5093-428-001
7G 2 AW FLOWMETER
(AW CABLE/4/T/8
5 4
CABLE AND SENSOR

BEARING AIR
SENSO000000473O P/I 4-20mA
ANALOG I/O ANALOG I/O COUNTER IN

S1
PWR PWRV MS NS
0 1 0 1 0 1 ST
2 3 2 3 2 3
SET T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
IN IN LOW SPEED SET T ING 3
0 1 0 1 0 1
BUS
2 3 2 3 2 3 IN
PCI
OUT OUT HIGH SPEED
[EG-00457] REV A
-250-
Figure 8-82 EG-00458 Sheet 1 of 4, P-700 SMC 2K 1+1 WITH REG SCHEMATIC
WARNING
REG1 4mm
I/P components. Otherwise you could
REG2 4mm
REG 1 injure personnel or damge equipment
2 3 TDUCO000000020 O
I/P
REG 1
TDUCO000000020 O
1 WARNING
1 before you perform any service or
PORT 1 PORT 3/5 equipment.
PLUGGED PLUGGED
6 mm
SV-24 SV-23 UNLESS OTHERWISE NOTED:
6 mm
6 mm
SV-02
FITTINGS SV-01
SV-24 - PLUGG ED P1
SV-23 - PLUGG ED
PLUGGED
SV-22 - PLUGG ED
E 3/5 PORT 1 PORT 3/5
SV-21 - pH1 4mm PLUGGED
EX600 LOCAL
SV-18 - PLUGG ED
SV-17 - pC1 4mm
SV-16 - PLUGG ED
SV-15 - PLUGG ED
10 mm
SV-14 - pFLUSH2 4mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - PLUGG ED
8 mm
SV-11 - SEAL 6mm
FITCO000001381O
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096 O
FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm 6 mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019 O
TURB1 10mm
1
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
SA2 10mm TDUCO000000019 O 10mm HPNMO000019117 O
SUPPLY MANIFOLD
CPX - 10MM
EO-6246-170-006
CARRIAGE AIR
BEAR 6mm
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 10MM
SENSO000000473O
SHAPE AIR 2 - 10MM
BEAR 8mm
[EG-00458] REV A
P-700 SMC 2K 1+1 WITH REG SCHEMATIC SHEET 1 OF 4
-251-
W A R N IN G
S om e co m p o ne nts are he a vy. U se
R E S IN O U T L E T P R E S S U R E (P 1 O P ) e xtrem e ca re a nd follow p ro pe r liftin g
p ro ced u res w he n yo u install o r re m o ve
C A T A LY S T O U T L E T P R E S S U R E (P 2O P ) co m p o n en ts. O th erw ise yo u co uld
in jure p erson n el or d a m g e e q uip m e nt
R E S IN IN L E T F L O W M E T E R (P 1 IM )
SEE NOTE 1
W A R N IN G
REG1
A lw ays d isco n ne ct p ow e r to th e ro b ot
b efo re you pe rfo rm a ny se rvice or
M IX EL E M E N T H O L D E R m a inte n an ce pro ced u res. O th e rw ise ,
EO -5 09 3 -51 6 -0 1 1 yo u co uld in ju re p e rso n ne l o r da m ag e
e qu ip m en t.
U N L E S S O T H E R W IS E N O T E D :
P A IN T LIN E T O B E L L
E O -50 9 3-5 1 6-0 1 0 E O -5 0 9 3-5 1 6-0 02 E O -5 09 3 -51 6 -00 8 S E E E G -0 0 00 8 F O R LO C T IT E R E Q U IR E M E N T S
C1
PUM P BLOCK S U P P L Y B LO C K D U M P B LO C K S E E E G -0 0 01 0 F O R T O R Q U E S P E C IF IC A T IO N S
CC RES
A IR
PUM P1
(R E S IN )
E O -5 0 93 -5 16 -0 04 PE
R E G U L A T O R B LO C K
FLOW M ETERS SOL
DUMP T R IG
F LU S H
IW
CAT
PUM P2
(C A T A L Y S T )
SOL2 BW
F LU S H 2
W A S H L IN E T O B EL L
H1
SO L
SOL
HS1
PS1
PR1
S O L2
A IR
REG2
DUM P TO W ASTE
R E C L A IM A T IO N
C A T A LY S T IN L ET F L O W M E T E R (P 2 IM )
SOL SEE NO TE 1
NOTES:
1 . IN L E T F L O W M ET E R S (E O -50 9 3-5 1 6-0 0 4) A R E R E P L A C E D W IT H IN L E T
P R E S S U R E S E N S O R S (E O -5 0 9 3-5 1 6-0 0 6) IN S O M E C O N F IG U R A T IO N S . T H E IN LE T
S E N S O R L A B E LS (P 1 IM & P 2 IM ) A R E R E P LA C E D W IT H P 1IP & P 2IP .
EO6246-895-003J SHOWN
CIRCULATING RESIN
INLET FLOW METERS
[E G -00 4 5 8] REV A
P -7 0 0 S M C 2K 1 + 1 W IT H R E G S C H E M A T IC S H E E T 2 O F 4
-252-
WARNING
2K 1+1 VAR REG WITH INLET PRESSURE SENSORS
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
CASCADE
EE-4696-625-003 QD
I.S. GROUND
JOINT 3
REG 2 KEYENCE
CBLEO000000386O I/P ITV 4-20mA
Z787
P2IP
CBLEO000000385O EE-5093-426-001 4-20mA
5 4
Z787 P1OP
REG 1 EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
CBLEO000000386O 7G 2
I/P ITV 4-20mA HONEYWELL I/P
5 4
SHAPE AIR 1 REG Z787 P2OP
EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
CBLEO000000384O I/P ITV 4-20mA 7G 2 HONEYWELL I/P
5 4
SHAPE AIR 1 FLOW SENSOR Z787 P1IP
EE-5093-426-001 4-20mA 8 1
CBLEO000000388O Q/I 4-20mA EE-4696-267-004
7G 2 HONEYWELL I/P
5 4
CABLE AND SENSOR

BEARING AIR
SENSO000000473O P/I 4-20mA

ST PWR PWRV MS NS
0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 SET T ING 1 SET T ING 2
COLOR VALVES

IN IN IN LOW SPEED
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI
[EG-00458] REV A
-253-
WARNING
2K 1+1 VAR REG WITH INLET FLOW SENSORS
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
CASCADE
EE-4696-625-003 QD
I.S. GROUND
JOINT 3
REG 2 KEYENCE
CBLEO000000386O I/P ITV 4-20mA
Z787
P2OP
CBLEO000000385O EE-5093-426-001 4-20mA
5 4
Z787 P1OP
REG 1 EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
CBLEO000000386O 7G 2
I/P ITV 4-20mA HONEYWELL I/P
5 4
SHAPE AIR 1 REG Z787 P1IM
EE-5093-424-001 4-20mA 8 1
CBLEO000000384O I/P ITV 4-20mA 7G 2
EE-5093-428-001 AW FLOWMETER
(AW CABLE/4/T/8
5 4
SHAPE AIR 1 FLOW SENSOR Z787 P2IM
EE-5093-424-001 4-20mA 8 1
CBLEO000000388O Q/I 4-20mA EE-5093-428-001
7G 2 AW FLOWMETER
(AW CABLE/4/T/8
5 4
CABLE AND SENSOR

BEARING AIR
SENSO000000473O P/I 4-20mA
ANALOG I/O ANALOG I/O

S1
PWR PWRV MS NS
0 1 0 1 0 1 ST
2 3 2 3 2 3
COUNTER IN
SET T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
IN IN SET T ING 3
0 1 0 1 0 SPEED 1
LOW
BUS
2 3 2 3 2 3 IN
PCI
OUT OUT
HIGH SPEED
[EG-00458] REV A
-254-
Figure 8-86 EG-00485 Sheet 1 of 4, P700 SMC 2K 24+3 SCHEMATIC FIXED REG
WARNING
S07-48 S07-47 components. Otherwise you could
WARNING
REMOTE
S07-48 - pC24 4mm
EX600
THRU maintenance procedures. Otherwise,
S07-34 S07-33 you could injure personnel or damage
equipment.
S07-33 - pC9 4mm P1
PORT 3/5 PORT 1
FITCO000001381O E 3/5 SEE EG-00008 FOR LOCTITE REQUIREMENTS
THRU INNER ARM WALL SEE EG-00010 FOR TORQUE SPECIFICATIONS
SV-32 - pC8 4mm
P1
SV-31 - pC7 4mm PLUGGED PORT 1 PORT 3/5
SV-30 - pC6 4mm PLUGGED PLUGGED
PLUGGED
SV-29 - pC5 4mm
E 3/5
SV-27 - pC3 4mm
SV-26 - pC2 4mm
SV-25 - pC1 4mm 8 mm TEE SV-32 SV-31
2X FITCO000001381O
SV-24 - PLUGGED FITTING
SV-23 - pH3 4mm
THRU AXIS 3 HOUSING
SV-22 - pH2 4mm
SV-21 - pH1 4mm 8 mm 8 mm
EX600 LOCAL
SV-18 - PLUGGED SV-02
SV-17 - pWASH 4mm
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm
SV-14 - pFLUSH2 4mm
10 mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
PORT 1 PORT 3/5
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 12MM
SENSO000000473O
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00485] REV B
P700 SMC 2K 24+3 SCHEMATIC FIXED REGSHEET 1 OF 4
-255-
W A R N IN G
S om e co m p o ne nts are he a vy. U se
e xtrem e ca re a nd follow p ro pe r liftin g
R E S IN O U T LE T P R E S S U R E (P 1 O P ) p ro ced u res w he n yo u install o r re m o ve
co m p o n en ts. O th erw ise yo u co uld
R E S IN IN L E T F L O W M E T E R (P 1 IM ) M IX E L E M E N T H O L D E R in jure p erson n el or d a m g e e q uip m e nt
C A T A LY S T O U T L E T P R E S S U R E (P 2O P )S E E N O T E 1 E O -5 0 9 3-5 1 6-0 11
W A R N IN G
P A IN T LIN E T O B E L L A lw ays d isco n ne ct p ow e r to th e ro b ot
E O -5 0 93 -5 16 -0 10 E O -5 0 93 -5 17 -0 04 E O -5 0 93 -5 17 -0 02 E O -5 0 93 -5 17 -0 08 b efo re you pe rfo rm a ny se rvice or
P U M P B LO C K REGULATOR BLOCK S U P P L Y B LO C K DUM P BLOCK m a inte n an ce pro ced u res. O th e rw ise ,
FLOW M ETERS yo u co uld in ju re p e rso n ne l o r da m ag e
e qu ip m en t.
DUM P2 RES
U N L E S S O T H E R W IS E N O T E D :
PUM P1 S E E E G -0 0 00 8 F O R LO C T IT E R E Q U IR E M E N T S
(R E S IN )
S E E E G -0 0 01 0 F O R T O R Q U E S P E C IF IC A T IO N S
PE
DUM P T R IG
FLUSH
IW
CAT
PUM P2
(C A T A L Y S T ) SO L2
BW
DUM P3
H3 H2 H1
FLUSH2
W ASH
W A S H LIN E T O B E L L
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
R E SIN F R O M IN N E R A R M
C A T A L Y ST IN L E T F L O W M E T E R (P 2 IM )
SEE NOTE 1 DUM P TO W ASTE
PR24
P S 24
PS22
PR22
R E C L A IM A T IO N
PS2
PR2
PR4
PS4
2 T F R O M IN N E R A R M
SO L
SOL
CC
A IR
A IR
NOTES:
2T 1. IN LE T F L O W M E T E R S (E O -5 0 93 -5 17 -0 04 ) A R E R E P LA C E D
W IT H IN L E T P R E S S U R E S E N S O R S (E O -5 09 3 -51 7 -00 6 ) IN S O M E
C O N F IG U R A T IO N S . T H E IN L E T S E N S O R LA B E L S (P 1IM & P 2 IM )
A R E R E P LA C E D W IT H P 1IP & P 2IP .
PS1
PR1
PS21
PR21
PS23
PR23
PR3
PS3
2T
E O -50 9 3-5 1 0-0 0 1

C IR C U L A T IN G C O LO R S T A C K
A D D IT IO N A L C O L O R S LIC E S H E R E EO5093-895-004BT SHOWN
INLET FLOW METERS
[E G -00 4 8 5] REV B
P 70 0 S M C 2K 2 4 + 3 S C H E M A T IC F IX E D R E GS H E E T 2 O F 4
-256-
WARNING

INLET FLOW METERS
OUTSIDE PAINT BOOTH INSIDE PAINT BOOTH SEE EG-00008 FOR LOCTITE REQUIREMENTS
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND
CABLE INCLUDED ON EE-4696-021 EE-4696-021 EE-4560-655-002 DUAL FIBER - EE-4560-654-003

KEYENCE DUAL FIBER
CBLEO000000385O
I/P ITV 4-20mA TURBINE DRIVE Z787
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
Z787
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
I/P ITV 4-20mA SHAPE AIR 1 7
G
2 HONEYWELL I/P
5 4
CBLEO000000388O Z787
Q/I 4-20mA SA 1 FLOW SENSOR RED P1IM
24V 8 1
EE-5093-424-001 EE-5093-428-001
0V 7 2 BLK A/W FLOW METER
G WHT
SIG- 5 4
R
Z787
RED P2IM
P/V 1-5V BEARING AIR EE-5093-424-001 24V 8 1
BLK EE-5093-428-001
0V 7 2 A/W FLOW METER
CABLE AND SENSOR - SENSO000000473O SIG- 5
G
4
WHT
R
NOTES:
SIG+ WIRE IS NOT CONNECTED
ON EE-5093-424-001 CABLE.
TIE BACK SIG+ WIRE TO CABLE
AND SHRINK AROUND CONDUCTOR.
SMC EX600 PROCESS I/O JUMPER THE I.S. GND TERMS
ON THE Z787 BARRIERS,
ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 16AWG MIN.
P WR PWRV MS NS
5.1K Ohm RESISTORS

ST
0 1 0 1 0 1 CONNECT DRAIN WIRES TO TYP (4) PL MARKED "R"

2 3 2 3 2 3 SE T T ING 1 SE T T ING 2 I.S. TERMINALS ON THE Z787 PUT LEADS IN BARREL
BARRIERS. CONNECTOR
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00485] REV B
-257-
WARNING
EO5093-895-004AF SHOWN
(24) RESIN - CIRCULATING WARNING
equipment.
INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
CBLEO000000385O
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
Z787
P2OP
8 1
CBLEO000000384O EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
Q/I 4-20mA SA 1 FLOW SENSOR Z787
P1IP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
Z787
P2IP
P/V 1-5V BEARING AIR EE-5093-426-001 4-20mA 8 1 EE-4696-267-004
7 2 HONEYWELL I/P
CABLE AND SENSOR - SENSO000000473O 5
G
4
NOTES:
16AWG MIN.
SMC EX600 PROCESS I/O CONNECT DRAIN WIRES TO
I.S. TERMINALS ON THE Z787
ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT
ST P WR PWRV MS
S1
NS
BARRIERS.
0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 S ET T ING 1 SE T T ING 2
COLOR VALVES
COLOR VALVES
SE T T ING 3
IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00485] REV B
-258-
Figure 8-90 EG-00486 Sheet 1 of 4, P700 SMC 2K 24+3 VAR REG SCHEMATIC
WARNING
REG1 4mm
REG 1
S07-48 S07-47 injure personnel or damge equipment
REG2 4mm 2 3 TDUCO000000020O
I/P
REG 1
TDUCO000000020O 1 WARNING
REMOTE
1
EX600
THRU you could injure personnel or damage
S07-34 S07-33 equipment.
S07-33 - pC9 4mm
P1
6 mm
PORT 3/5 SEE EG-00008 FOR LOCTITE REQUIREMENTS
6 mm
E 3/5
6 mm
SV-32 - pC8 4mm
P1
PLUGGED
THRU PORT 1 PORT 3/5
E 3/5 8 mm FITTINGS PLUGGED PLUGGED
PLUGGED
SV-25 - pC1 4mm
SV-32 SV-31
SV-24 - PLUGGED
SV-23 - pH3 4mm
2X FITCO000001381O SV-22 - pH2 4mm

8 mm
THRU AXIS 3 SV-21 - pH1 4mm
HOUSING SV-20 - pCAT 4mm FITTING
EX600 LOCAL
SV-18 - PLUGGED
SV-17 - pWASH 4mm SV-02
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm
SV-14 - pFLUSH2 4mm
10 mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
PORT 1 PORT 3/5
FITCO000001381O
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
CPX - 10MM
SUPPLY MANIFOLD
EO-6246-170-006
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SHAPE AIR 1 - 12MM
SENSO000000473O
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00486] REV B
P700 SMC 2K 24+3 VAR REG SCHEMATIC SHEET 1 OF 4
-259-
WARNING
WARNING
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

REG2
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
REG
PR2
PS2
RECLAIMATION
PS4
PR4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
2T
NOTES:

PR1
PS1
PR21
PS21
PR23
PS23
PS3
PR3

2T
EO-5093-510-001
INLET FLOW METERS
[EG-00486] REV B
-260-
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
CBLEO000000385O REGULATOR 2
I/P ITV 4-20mA
CBLEO000000385O
P1OP
CBLEO000000385O 8 1
I/P ITV 4-20mA REGULATOR 1 EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
Z787
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
RED P1IM
24V 8 1
EE-5093-424-001 BLK EE-5093-428-001
G WHT
SIG- 5 4
R
Z787
RED P2IM
P/V 1-5V BEARING AIR EE-5093-424-001 24V 8 1 EE-5093-428-001
G
4
WHT
R
NOTES:
ON EE-5093-424-001 CABLE.
ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 16AWG MIN.
PWR PWRV MS NS
5.1K Ohm RESISTORS

ST

2 3 2 3 2 3 SET T ING 1 SE T T ING 2 I.S. TERMINALS ON THE Z787 PUT LEADS IN BARREL
BARRIERS. CONNECTOR
COLOR VALVES

IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00486] REV B
-261-
WARNING
equipment.

EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
I/P ITV 4-20mA
CBLEO000000385O
P1OP
CBLEO000000385O 8 1
REGULATOR 1 EE-5093-426-001 4-20mA EE-4696-267-004
I/P ITV 4-20mA 7
G
2 HONEYWELL I/P
5 4
Z787
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
P1IP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
Z787
P2IP
7 2 HONEYWELL I/P
G
4
NOTES:
16AWG MIN.

ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 BARRIERS.
ST PWR PWRV MS NS
0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 SET T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00486] REV B
-262-
Figure 8-94 EG-00494 Sheet 1 of 4, P-500iA SMC 2K 24+3 VAR REG SCHEMAT
WARNING
REG1 4mm
REG 1
REG2 4mm 2 3 TDUCO000000020O
I/P
REG 1
1
6 mm
6 mm
6 mm
SV-32 - pC8 4mm
P1
PLUGGED
E 3/5 FITTINGS PLUGGED PLUGGED
PLUGGED
SV-25 - pC1 4mm
SV-32 SV-31
SV-24 - PLUGGED
SV-23 - pH3 4mm
SV-22 - pH2 4mm

SV-21 - pH1 4mm
EX600 LOCAL
SV-18 - PLUGGED
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm
SV-14 - pFLUSH2 4mm
10 mm
8 mm
24X FITCO000001381O SV-13 - pSOL2 4mm E 3/5
THRU CARRIAGE SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
PORT 1 PORT 3/5
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
SV-06 - pSOL 4mm
EXHAUST MANIFOLD
FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH
SA1 10mm 3 SHAPE AIR

I/P
SA2 10mm TDUCO000000019O HPNMO000019117O
PROCESS AIR SUPPLY 1 - 12MM
CARRIAGE ROX
BEAR 6mm
TBSP1 - 12MM
TBSP2 - 12MM
BEAR P/I 8 mm
SENSO000000473O
BEAR 8mm
[EG-00494] REV A
P-500iA SMC 2K 24+3 VAR REG SCHEMAT SHEET 1 OF 4
-263-
WARNING
MIX ELEMENT HOLDER injure personnel or damge equipment
CATALYST OUTLET PRESSURE (P2OP) EO-5093-516-011
SEE NOTE 1 WARNING
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

REG2
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
SEE NOTE 1
DUMP TO WASTE
REG
PR8
PS8
PR2
PS2
RECLAIMATION
PR6
PS6
PR4
PS4
SOL
SOL RESIN IN
CC
2T
AIR
AIR
2T
NOTES:

PR1
PS1
PS3
PR3
PR5

PS5
PR7
PS7
2T
EO-5093-510-001
ADDITIONAL COLOR SLICES HERE EO6393-895-004AP SHOWN
INLET FLOW METERS
[EG-00494] REV A
-264-
WARNING
EO6393-895-004AP SHOWN components. Otherwise you could
OUTSIDE PAINT BOOTH INSIDE PAINT BOOTH
REF - EE-6246-207-XXX
LOW VOLTAGE CABLE equipment.

REF - EE-6102-161-XXX
ETHERNET
REF - EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
REF.
JOINT 3 CASCADE
EE-4696-625-XXX QD
I.S. GROUND
CABLE INCLUDED ON EE-4696-021 EE-4696-021 REF- EE-4560-655-001 DUAL FIBER - EE-4560-654-XXX

KEYENCE DUAL FIBER REF.
CBLEO000000384O
I/P ITV 4-20mA REGULATOR 2
CBLEO000000384O
P1OP
CBLEO000000384O EE-5093-426-001 4-20mA
8 1 EE-4696-267-002
I/P ITV 4-20mA REGULATOR 1 7
G
2 HONEYWELL I/P
5 4
Z787
P2OP
CBLEO000000384O EE-5093-426-001 4-20mA
8 1 EE-4696-267-002
I/P ITV 4-20mA SHAPE AIR 1 7 2 HONEYWELL I/P
G
5 4
CBLEO000000388O Z787
Q/I 4-20mA SA 1 FLOW SENSOR P1IM
EE-5093-424-001 24V 8 1 RED EE-5093-428-002
G
SIG- 5 4 WHT
R
Z787
P2IM
P/V 1-5V BEARING AIR EE-5093-424-001
24V 8 1 RED EE-5093-428-002
BLK
CABLE AND SENSOR - SENSO000000473O SIG- G WHT
5 4
R
NOTES:
ON EE-5093-424-001 CABLE.

ANALOG I/O ANALOG I/O COUNTER IN S1 16AWG MIN.
ST PWR PWRV MS NS
1 1 CONNECT DRAIN WIRES TO

5.1K Ohm RESISTORS
0 1 0 0
TYP (4) PL MARKED "R"
COLOR VALVES
3 2 3 3 I.S. TERMINALS ON THE Z787

COLOR VALVES
2 2 SET T ING 1 SE T T ING 2
BARRIERS.
PUT LEADS IN BARREL
CONNECTOR
SET T ING 3
IN IN LOW SPEED
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
[EG-00494] REV A
-265-
WARNING
EO6393-895-004A SHOWN components. Otherwise you could
REF - EE-6246-207-XXX
LOW VOLTAGE CABLE equipment.

REF - EE-6102-161-XXX
ETHERNET
REF - EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
REF.
JOINT 3 CASCADE
EE-4696-625-XXX QD
I.S. GROUND
CABLE INCLUDED ON EE-4696-021 EE-4696-021 REF - EE-4560-655-001 DUAL FIBER - EE-4560-654-XXX

CBLEO000000384O
I/P ITV 4-20mA REGULATOR 2
CBLEO000000384O
P1OP
CBLEO000000384O EE-5093-426-001 4-20mA
8 1 EE-4696-267-002
I/P ITV 4-20mA REGULATOR 1 7
G
2 HONEYWELL I/P
5 4
Z787
P2OP
CBLEO000000384O EE-5093-426-001 8 1 EE-4696-267-002
4-20mA
I/P ITV 4-20mA SHAPE AIR 1 7 2 HONEYWELL I/P
G
5 4
CBLEO000000388O Z787
Q/I 4-20mA SA 1 FLOW SENSOR P1IP
EE-5093-426-001 4-20mA
8 1 EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
Z787
P2IP
P/V 1-5V BEARING AIR EE-5093-426-001 4-20mA
8 1 EE-4696-267-002
7 2 HONEYWELL I/P
CABLE AND SENSOR - SENSO000000473O G
5 4
NOTES:

16AWG MIN.
ST PWR PWRV MS NS
BARRIERS.
0 1 0 1 0 1 0 1
COLOR VALVES
2 3 2 3 2 3 2 3
COLOR VALVES
S ET T ING 1 S ET T ING 2
S ET T ING 3
IN IN IN LOW SPEED
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI
[EG-00494] REV A
-266-
Figure 8-98 EG-00495 Sheet 1 of 4, P-500iA SMC 2K 24+3 FIXED REG SCHEM
WARNING
WARNING

SV-32 - pC8 4mm

P1
PLUGGED
E 3/5 PLUGGED PLUGGED
PLUGGED
SV-25 - pC1 4mm
SV-32 SV-31
SV-24 - PLUGGED
SV-23 - pH3 4mm
SV-22 - pH2 4mm

SV-21 - pH1 4mm
SV-20 - pCAT 4mm
SV-19 - pRES 4mm
EX600 LOCAL
SV-18 - PLUGGED
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm
SV-14 - pFLUSH2 4mm

8 mm
24X FITCO000001381O SV-13 - pSOL2 4mm E 3/5
THRU CARRIAGE SV-12 - pDUMP2 4mm
SV-11 - SEAL 6mm

PORT 1 PORT 3/5
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
SV-06 - pSOL 4mm
EXHAUST MANIFOLD
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH
SA1 10mm 3 SHAPE AIR

I/P
SA2 10mm TDUCO000000019O HPNMO000019117O
CARRIAGE ROX
BEAR 6mm
TBSP1 - 12MM
TBSP2 - 12MM
BEAR P/I 8 mm
SENSO000000473O
BEAR 8mm
[EG-00495] REV A
P-500iA SMC 2K 24+3 FIXED REG SCHEM SHEET 1 OF 4
-267-
WARNING
MIX ELEMENT HOLDER injure personnel or damge equipment
CATALYST OUTLET PRESSURE (P2OP) RESIN INLET FLOW METER (P1IM) EO-5093-516-011
SEE NOTE 1 WARNING
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
SEE NOTE 1
DUMP TO WASTE
PR8
PS8
PR2
PS2
RECLAIMATION
PR6
PS6
PR4
PS4
SOL
SOL RESIN IN
CC
2T
AIR
AIR
2T
NOTES:

PR1
PS1
PS3
PR3
PR5

PS5
PR7
PS7
2T
EO-5093-510-001
ADDITIONAL COLOR SLICES HERE EO6393-895-004BP SHOWN
INLET FLOW METERS
[EG-00495] REV A
-268-
WARNING
EO6393-895-004AP SHOWN components. Otherwise you could
OUTSIDE PAINT BOOTH INSIDE PAINT BOOTH (8) RESIN - CIRCULATING
REF - EE-6246-207-XXX FIXED PRESSURE REGULATORS Always disconnect power to the robot
LOW VOLTAGE CABLE
equipment.

REF - EE-6102-161-XXX
ETHERNET
REF - EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
REF.
JOINT 3 CASCADE
EE-4696-625-XXX QD
I.S. GROUND
CABLE INCLUDED ON EE-4696-021 EE-4696-021 REF- EE-4560-655-001 DUAL FIBER - EE-4560-654-XXX

CBLEO000000384O
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
Z787
P2OP
8 1
CBLEO000000384O EE-5093-426-001 4-20mA EE-4696-267-002
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
RED P1IM
24V 8 1
EE-5093-424-001 BLK EE-5093-428-002
G WHT
SIG- 5 4
R
Z787
RED P2IM
BLK EE-5093-428-002
G
4
WHT
R
NOTES:
ON EE-5093-424-001 CABLE.
ANALOG I/O ANALOG I/O COUNTER IN S1 16AWG MIN.
P WR PW RV M S NS
5.1K Ohm RESISTORS

ST

2 3 2 3 2 3 S ET T ING 1 SET T ING 2 I.S. TERMINALS ON THE Z787 PUT LEADS IN BARREL
BARRIERS.
COLOR VALVES
CONNECTOR
COLOR VALVES
SE T T ING 3
IN IN LOW SPEED
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
[EG-00495] REV A
-269-
WARNING
INSIDE PAINT BOOTH EO6393-895-004A SHOWN components. Otherwise you could
REF - EE-6246-207-XXX
LOW VOLTAGE CABLE
equipment.

REF - EE-6102-161-XXX
ETHERNET
REF - EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
REF.
JOINT 3 CASCADE
EE-4696-625-XXX QD
I.S. GROUND
CABLE INCLUDED ON EE-4696-021 EE-4696-021 REF - EE-4560-655-001 DUAL FIBER - EE-4560-654-XXX

CBLEO000000384O
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
Z787
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-002
G
2 HONEYWELL I/P
5 4
CBLEO000000388O Z787
Q/I 4-20mA SA 1 FLOW SENSOR P1IP
8 1
EE-5093-426-001 4-20mA EE-4696-267-002
7 2 HONEYWELL I/P
G
5 4
Z787
P2IP
7 2 HONEYWELL I/P
G
4

ST PW R PWRV MS NS
0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 SET T ING 1 SE T T ING 2
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN LOW SPEED
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI
[EG-00495] REV A
-270-
Figure 8-102 EG-00499 Sheet 1 of 4, P700 SMC DUAL SA 2K 24+3 SCHEMATIC FIXED REG
WARNING
S07-48 S07-47 components. Otherwise you could
WARNING
REMOTE
S07-48 - pC24 4mm
EX600
THRU maintenance procedures. Otherwise,
S07-34 S07-33 you could injure personnel or damage
equipment.
S07-33 - pC9 4mm P1
PORT 3/5 PORT 1
FITCO000001381O E 3/5 SEE EG-00008 FOR LOCTITE REQUIREMENTS
THRU INNER ARM WALL SEE EG-00010 FOR TORQUE SPECIFICATIONS
SV-32 - pC8 4mm
P1
SV-31 - pC7 4mm PLUGGED PORT 1 PORT 3/5
SV-30 - pC6 4mm PLUGGED PLUGGED
PLUGGED
SV-29 - pC5 4mm
E 3/5
SV-27 - pC3 4mm
SV-26 - pC2 4mm
SV-25 - pC1 4mm 8 mm TEE SV-32 SV-31
2X FITCO000001381O
SV-24 - PLUGGED FITTING
SV-23 - pH3 4mm
THRU AXIS 3 HOUSING
SV-22 - pH2 4mm
SV-21 - pH1 4mm 8 mm 8 mm
EX600 LOCAL
SV-18 - PLUGGED SV-02
SV-17 - pWASH 4mm
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm

SV-14 - pFLUSH2 4mm
10 mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
PORT 1 PORT 3/5
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
6 mm 10 mm
EXHAUST TO
3 6 mm BOOTH
SA1 10mm 2 I/P 1 12mm SHAPE AIR
SHAPE AIR FLOW SENSOR
TDUCO000000019O HPNMO000019116O
6 mm
CPX - 10MM
SUPPLY MANIFOLD
EO-6246-170-006
3
CARRIAGE AIR
I/P SHAPE AIR
SA2 10mm 2 SHAPE AIR 1 10mm FLOW SENSOR TBSP1 - 10MM
TDUCO000000019O HPNMO000019116O
TBSP2 - 10MM
SHAPE AIR 1 - 12MM

BEAR 6mm
SHAPE AIR 2 - 12MM
BEAR P/I 8 mm
BEAR 8mm
SENSO000000473O
[EG-00499] REV A
P700 SMC DUAL SA 2K 24+3 SCHEMATIC SHEET 1 OF 4
FIXED REG
-271-
WARNING
CATALYST OUTLET PRESSURE (P2OP)SEE NOTE 1 EO-5093-516-011
WARNING
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
PS2
PR2
RECLAIMATION
PR4
PS4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
NOTES:
PS1
PR1
PS21
PR21
PS23
PR23
PR3
PS3
2T
EO-5093-510-001
INLET FLOW METERS
[EG-00499] REV A
FIXED REG
-272-
WARNING

INLET FLOW METERS
INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
CBLEO000000385O
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
I/P ITV 4-20mA SHAPE AIR 2 Z787
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
RED P1IM
24V 8 1
CBLEO000000388O EE-5093-424-001 EE-5093-428-001
Q/I 4-20mA SA 2 FLOW SENSOR 0V 7 2 BLK A/W FLOW METER
G WHT
SIG- 5 4
R
Z787
RED P2IM
P/V 1-5V BEARING AIR EE-5093-424-001 24V 8 1 EE-5093-428-001
G
4
WHT
R
NOTES:
ON EE-5093-424-001 CABLE.
ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 16AWG MIN.
PWR PWRV MS NS
5.1K Ohm RESISTORS

ST
0 1 0 1 0 1 0 1 CONNECT DRAIN WIRES TO TYP (4) PL MARKED "R"

2 3 2 3 2 3 2 3 SET T ING 1 SET T ING 2 I.S. TERMINALS ON THE Z787 PUT LEADS IN BARREL
BARRIERS. CONNECTOR
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00499] REV A
FIXED REG
-273-
WARNING
EO6246-896-004AF SHOWN
(24) RESIN - CIRCULATING WARNING
equipment.
INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
CBLEO000000385O
P1OP
8 1
EE-5093-426-001 4-20mA EE-4696-267-004
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
P1IP
8 1
CBLEO000000388O EE-5093-426-001 4-20mA EE-4696-267-004
Q/I 4-20mA SA 2 FLOW SENSOR 7
G
2 HONEYWELL I/P
5 4
Z787
P2IP
7 2 HONEYWELL I/P
G
4
NOTES:
16AWG MIN.
CONNECT DRAIN WIRES TO
SMC EX600 PROCESS I/O I.S. TERMINALS ON THE Z787
BARRIERS.
ANALOG I/O ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1
ST PW R PWRV MS NS
0 1 0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 2 3 SE T T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 2 3 PCI
OUT OUT OUT OUT HIGH SPEED

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00499] REV A
FIXED REG
-274-
Figure 8-106 EG-00500 Sheet 1 of 4, P700 SMC DUAL SA 2K 24+3 VAR REG SCHEMATIC
WARNING
REG1 4mm
REG 1
REG2 4mm 2 3 TDUCO000000020O
I/P
REG 1
REMOTE
1
EX600
THRU you could injure personnel or damage
S07-33 - pC9 4mm
P1
6 mm
6 mm
E 3/5
6 mm
SV-32 - pC8 4mm
P1
PLUGGED
E 3/5 8 mm FITTINGS PLUGGED PLUGGED
PLUGGED
SV-25 - pC1 4mm
SV-32 SV-31
SV-24 - PLUGGED
SV-23 - pH3 4mm
2X FITCO000001381O SV-22 - pH2 4mm

8 mm
THRU AXIS 3 SV-21 - pH1 4mm
HOUSING SV-20 - pCAT 4mm FITTING
EX600 LOCAL
SV-18 - PLUGGED
SV-01
SV-16 - p2T 4mm
SV-15 - pDUMP3 4mm
SV-14 - pFLUSH2 4mm
10 mm
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
PORT 1 PORT 3/5
FITCO000001381O
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
6 mm
6 mm 10 mm
EXHAUST TO
3 6 mm BOOTH
SA1 10mm 2 I/P 1 12mm SHAPE AIR
SHAPE AIR FLOW SENSOR
TDUCO000000019O HPNMO000019117O
6 mm
CPX - 10MM
SUPPLY MANIFOLD
3
EO-6246-170-006
CARRIAGE AIR
SA2 10mm 2 I/P SHAPE AIR
1 10mm FLOW SENSOR TBSP1 - 10MM
SHAPE AIR
HPNMO000019117O
TDUCO000000019O
TBSP2 - 10MM
SHAPE AIR 1 - 12MM

BEAR 6mm
SHAPE AIR 2 - 12MM
BEAR P/I 8 mm BEAR 8mm

SENSO000000473O
[EG-00500] REV A
P700 SMC DUAL SA 2K 24+3 VAR REG SHEET 1 OF 4
SCHEMATIC
-275-
WARNING
WARNING
equipment.
DUMP2 RES
(RESIN)
PE
DUMP TRIG
FLUSH
IW
CAT
PUMP2
(CATALYST) SOL2
BW
DUMP3
H3 H2 H1
FLUSH2
WASH
WASH LINE TO BELL

REG2
SOL
HS1
HR1
HR3
SOL
HS3
HR2
HS2
SOL2
PR24
PS24
PR22
PS22
REG
PS2
PR2
RECLAIMATION
PR4
PS4
2T FROM INNER ARM

SOL
SOL
CC
AIR
AIR
2T
NOTES:

PS1
PR1
PS21
PR21
PS23
PR23
PR3
PS3

2T
EO-5093-510-001
INLET FLOW METERS
[EG-00500] REV A
SCHEMATIC
-276-
WARNING
equipment.

EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
I/P ITV 4-20mA
CBLEO000000385O
P1OP
CBLEO000000385O 8 1
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
RED P1IM
24V 8 1
CBLEO000000388O EE-5093-424-001 BLK EE-5093-428-001
Q/I 4-20mA SA 2 FLOW SENSOR 0V 7
G
2
WHT
A/W FLOW METER
SIG- 5 4
R
Z787
RED P2IM
BLK EE-5093-428-001
G
4
WHT
R
NOTES:
ON EE-5093-424-001 CABLE.
ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1 16AWG MIN.
PWR P WRV MS NS
5.1K Ohm RESISTORS

ST
0 1 0 1 0 1 0 1 CONNECT DRAIN WIRES TO TYP (4) PL MARKED "R"

2 3 2 3 2 3 2 3 SET T ING 1 SET T ING 2 I.S. TERMINALS ON THE Z787 PUT LEADS IN BARREL
BARRIERS. CONNECTOR
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 PCI

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00500] REV A
SCHEMATIC
-277-
WARNING
equipment.

EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3 CASCADE
EE-4696-625-003 QD
I.S. GROUND

KEYENCE DUAL FIBER
I/P ITV 4-20mA
CBLEO000000385O
P1OP
CBLEO000000385O 8 1
7 2 HONEYWELL I/P
G
5 4
CBLEO000000384O
P2OP
CBLEO000000384O 8 1
EE-5093-426-001 4-20mA EE-4696-267-004
G
2 HONEYWELL I/P
5 4
CBLEO000000388O
P1IP
8 1
CBLEO000000388O EE-5093-426-001 4-20mA EE-4696-267-004
Q/I 4-20mA SA 2 FLOW SENSOR 7
G
2 HONEYWELL I/P
5 4
Z787
P2IP
7 2 HONEYWELL I/P
G
4
NOTES:
16AWG MIN.
CONNECT DRAIN WIRES TO
SMC EX600 PROCESS I/O I.S. TERMINALS ON THE Z787
BARRIERS.
ANALOG I/O ANALOG I/O ANALOG I/O ANALOG I/O COUNTER IN 24 DIGITAL OUT S1
ST PW R PWRV MS NS
0 1 0 1 0 1 0 1 0 1
2 3 2 3 2 3 2 3 2 3 SE T T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
SET T ING 3
IN IN IN IN LOW SPEED
D-SUB 25 PIN
0 1 0 1 0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 2 3 2 3 PCI
OUT OUT OUT OUT HIGH SPEED

CC VALVES
D-SUB 25 PIN
CC VALVES
CBLEO000000387O
[EG-00500] REV A
SCHEMATIC
-278-
Figure 8-110 EG-00513 Sheet 1 of 3, P-250iB 1K WITH REG SCHEMATICS
WARNING
FRP 6 mm extreme care and follow proper lifting
PROCESS REG1 4mm
PLATE I/P components. Otherwise you could
TURRET PROCESS PLATE EO-6263-5XX-000

REG 1
TDUCO000000020O
S07-40 - pC24 4mm
REMOTE
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
6 mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-01
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-13 - PLUGGED E 3/5
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
FRP SUPPLY BLOCK EO-6263-5XX-000
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH

I/P
CPX - 10MM
BEAR 6mm
FITTING TBSP1 - 10MM SHAPE AIR SUPPLY - 10MM
EO-6263-115-002
PEDESTAL SUPPLY
SHAPE AIR SUPPLY - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm TURBINE SUPPLY - 10MM
SHAPE AIR 1 - 12MM
SENSO000000473O
TURBINE SUPPLY - 10MM
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00513] REV A
P-250iB 1K WITH REG SCHEMATICS SHEET 1 OF 3
-279-
WARNING
WARNING
equipment.

COLOR CHANGER (24 COLOR MAX) SEE EG-00010 FOR TORQUE SPECIFICATIONS
DUMP
DUMP
SOL PS4 PR4 REG RECOVERY
PS2 PR2
pC4 pC2
pDUMP PAINT
pPE
pTRIG
pSOL
pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00513] REV A
-280-
WARNING
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW
CBLEO000000039XO EE-6102-161-XXX
FIBER ETHERNET
EE-6263-306-001
24V POWER
PEDESTAL
ENTRANCE
JOINT 1 JOINT 2
AREA
EE-6263-202-XXX
CLASS 1
24V DIVISION 1
PROCESS EE-6263-102-XXX
24V POWER GROUP C,D,E,F
POWER
24V POWER
EE-6102-271-XXX
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-005
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000388O

4-20mA

ST PWR PWRV MS NS
0 1 0 1 0 1
COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00513] REV A
-281-
Figure 8-113 EG-00514 Sheet 1 of 3, P-250iB SINGLE SA 1K FIX REG SCHEMATICS
WARNING

S07-40 - pC24 4mm
REMOTE
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-01
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
10 mm
EXHAUST TO
6 mm 6 mm BOOTH
SA1 10mm 3 12mm

I/P SHAPE AIR
CPX - 10MM
BEAR 6mm
FITTING TBSP1 - 10MM SHAPE AIR SUPPLY - 10MM
EO-6263-115-002
PEDESTAL SUPPLY
TBSP2 - 10MM
BEAR P/I 8 mm TURBINE SUPPLY - 10MM
SHAPE AIR 1 - 12MM
SENSO000000473O
SHAPE AIR 2 - 12MM
BEAR 8mm
[EG-00514] REV B
P-250iB SINGLE SA 1K FIX REG SHEET 1 OF 3
SCHEMATICS
-282-
WARNING
WARNING
equipment.

DUMP
DUMP
SOL PS4 PR4 RECOVERY
PS2 PR2
pC4 pC2
pDUMP PAINT
pPE
FIXED pTRIG
pSOL REGULATOR
15 OR pIW
30PSI
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00514] REV B
SCHEMATICS
-283-
WARNING
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW
CBLEO000000039XO EE-6102-161-XXX
FIBER ETHERNET
EE-6263-306-001
24V POWER
PEDESTAL
ENTRANCE
JOINT 1 JOINT 2
AREA
EE-6263-202-XXX
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-6102-271-XXX
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-005
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
CBLEO000000384O
CBLEO000000388O

ST PWR P WRV MS NS
0 1 0 1 0 1
COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00514] REV B
SCHEMATICS
-284-
Figure 8-116 EG-00515 Sheet 1 of 3, P-250iB 1K DUAL SA WITH REG SCHEMATICS
WARNING
FRP 6 mm extreme care and follow proper lifting
PROCESS REG1 4mm
PLATE I/P components. Otherwise you could

REG 1
TDUCO000000020O
S07-40 - pC24 4mm
REMOTE
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
6 mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-01
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3 6 mm
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
6 mm 6 mm
10 mm
3 EXHAUST TO
SA1 10mm 2 I/P 1 SHAPE AIR 1
SHAPE AIR 1 12mm FLOW SENSOR 6 mm BOOTH
TDUCO000000019O HPNMO000019117O
6 mm
CPX - 10MM
3
SA2 10mm 2 I/P 1 12mm SHAPE AIR 2 TBSP1 - 10MM SHAPE AIR SUPPLY - 10MM
EO-6263-115-002
SHAPE AIR 2 FLOW SENSOR
PEDESTAL SUPPLY
TDUCO000000019O HPNMO000019117O SHAPE AIR SUPPLY - 10MM
TBSP2 - 10MM
SHAPE AIR 1 - 12MM
BEAR 6mm TURBINE SUPPLY - 10MM
FITTING
SHAPE AIR 2 - 12MM
BEAR 8mm
BEAR P/I 8 mm
SENSO000000473O
[EG-00515] REV B
P-250iB 1K DUAL SA WITH REG SHEET 1 OF 3
SCHEMATICS
-285-
WARNING
WARNING
equipment.

DUMP
DUMP
SOL PS4 PR4 REG RECOVERY
PS2 PR2
pC4 pC2
pDUMP PAINT
pPE
pTRIG
pSOL
pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00515] REV B
SCHEMATICS
-286-
WARNING
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW
CBLEO000000039XO EE-6102-161-XXX
FIBER ETHERNET
EE-6263-306-001
24V POWER
PEDESTAL
ENTRANCE
JOINT 1 JOINT 2
AREA
EE-6263-202-XXX
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-6102-271-XXX
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-005
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000384O
CBLEO000000388O
CBLEO000000388O

ST PWR P WRV MS NS
0 1 0 1 0 1
COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00515] REV B
SCHEMATICS
-287-
Figure 8-119 EG-00516 Sheet 1 of 3, P-250iB 1K DUAL SA FIXED REG SCHEMATICS
WARNING

S07-40 - pC24 4mm
REMOTE
EX600
S07V-36 - pC20 4mm
S07-35 - pC19 4mm
S07-34 - pC18 4mm
equipment.
P1
S07-33 - pC17 4mm
SV-32 - pC16 4mm
P1
SV-30 - pC14 4mm
SV-29 - pC13 4mm
E 3/5 SV-32 SV-31
SV-27 - pC11 4mm
SV-26 - pC10 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm SV-02
SV-01
EX600 LOCAL
SV-18 - pC2 4mm
SV-17 - pC1 4mm
SV-16 - PLUGGED
SV-15 - PLUGGED
PORT 1 PORT 3/5
10 mm
SV-12 - pDUMP2 4mm
8 mm
SV-11 - SEAL 6mm
SV-10 - pFLUSH 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1 FITTINGS
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
TURB2 10mm
6 mm 6 mm
I/P 3
2 TURBINE
TDUCO000000019O
1
TURB1 10mm
6 mm 6 mm
10 mm
3 EXHAUST TO
SA1 10mm 2 I/P 1 SHAPE AIR 1
SHAPE AIR 1 12mm FLOW SENSOR 6 mm BOOTH
TDUCO000000019O HPNMO000019117O
6 mm
CPX - 10MM
3
SA2 10mm 2 I/P 1 12mm SHAPE AIR 2 TBSP1 - 10MM SHAPE AIR SUPPLY - 10MM
EO-6263-115-002
PEDESTAL SUPPLY
TDUCO000000019O HPNMO000019117O SHAPE AIR SUPPLY - 10MM
TBSP2 - 10MM
SHAPE AIR 1 - 12MM
BEAR 6mm TURBINE SUPPLY - 10MM
FITTING
SHAPE AIR 2 - 12MM
BEAR 8mm
BEAR P/I 8 mm
SENSO000000473O
[EG-00516] REV B
P-250iB 1K DUAL SA FIXED REG SHEET 1 OF 3
SCHEMATICS
-288-
WARNING
WARNING
equipment.

DUMP
DUMP
SOL PS4 PR4 RECOVERY
PS2 PR2
pC4 pC2
pDUMP PAINT
pPE
FIXED
REGULATOR pTRIG
pSOL
15 OR
30 PSI pIW
INJECTOR
P/I
AIR
pBW
BELL WASH
2T
pAIR
pCC pC3 pC1 pVENT

pFLUSH
PS3 PR3 PS1 PR1
WASH

[EG-00516] REV B
SCHEMATICS
-289-
WARNING
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW
CBLEO000000039XO EE-6102-161-XXX
FIBER ETHERNET
EE-6263-306-001
24V POWER
PEDESTAL
ENTRANCE
JOINT 1 JOINT 2
AREA
EE-6263-202-XXX
CLASS 1
24V DIVISION 1
POWER
24V POWER
EE-6102-271-XXX
I.S. GROUND
JOINT 3
CASCADE
EE-4696-625-00X QD
HIGH VOLTAGE CABLE
Z787
1K PRES
EE-5093-426-001 4-20mA
8 1 EE-4696-267-005
7 2 HONEYWELL I/P
G
5 4
KEYENCE
CBLEO000000385O
CBLEO000000384O
CBLEO000000384O
CBLEO000000388O
CBLEO000000388O

ST PWR P WRV MS NS
0 1 0 1 0 1
COLOR VALVES
CC VALVES
LOW SPEED
D-SUB 25 PIN
CC VALVES
IN IN
D-SUB 25 PIN
0 1 0 1 0 1
BUS
IN
2 3 2 3 2 3 PCI
OUT OUT HIGH SPEED
CBLEO000000387O
[EG-00516] REV B
SCHEMATICS
-290-
8.2.2 1K Pump Manifold Block

EO-5093-521-000 (1K Pump Manifold) used on P-700 robots is located on the outer arm of the robot. It houses 4 paint valves (EO-5513-002-001). The block is connected to the pump manifold with 4 screws (SSHCM006-G). This
connection also mounts the pump block to the outer arm. EO-6102-521-000 (1K Pump Manifold) used on P-500 robots is located on the outer arm of the robot. It houses 3.paint valves (EO-5513-002-001). The block is connected to
the pump manifold with 4 screws (SSHCM006-G). This connection also mounts the pump block to the outer arm.
Figure 8-122 EO-5093-521-000, PUMP MANIFOLD ASSEMBLY
WARNING
2X EO9999-200-003C procedures when you install or remove
2X EO9999-200-001B components. Otherwise you could
SEE NOTE 3 SEE NOTE 3
WARNING
equipment.

2X EO9999-200-001E SEE EG-00010 FOR TORQUE SPECIFICATIONS
SEE NOTE 3
4X EO9999-200-003C
3X EO9999-200-001B
SEE NOTE 3
4X SSHCM006100055G
EO9999-200-001K
SEE NOTE 3
EO9999-750-007A
4X EO9999-200-005Q
SEE NOTE 2 EO-5093-521-002
4X EO-5513-002-000
SEE NOTE 4
NOTES:
1. DO NOT OVER TORQUE MICROVALVES (EO-5513-002-000).
DAMAGE TO THE MICROVALVE MAY OCCUR. MAXIMUM
TORQUE IS 45 IN-LBS. MICROVALVE INDICATOR SHOULD BE
FLUSH WITH MICROVALVE CAP WHEN INSTALLED PROPERLY.
USE EO-5513-700-003 (VALVE TOOL) TO INSTALL & REMOVE
MICROVALVES.
2. O-RINGS USED TO CAPTURE THE SOCKET HEAD SCREWS.
3. LUBRICATE O-RING WITH A THIN COAT OF DIELECTRIC
GREASE (EO-4526-050-009) PRIOR TO INSTALLATION.
4. APPLY A THIN COAT OF DIELECTRIC GREASE (EO-4526-050-009) Standard Hardware Descriptions
TO THE VALVE OUTER SURFACE AND THE VALVE SOCKET FANUC Part No. Description
PRIOR TO INSTALLATION SSHCM006100055G M6 X 1.0 X 55mm LG. Glass Filled Nylon Socket Head Cap
[EO-5093-521-000] REV C2
PUMP MANIFOLD ASSEMBLY SHEET 1 OF 1
-291-
Figure 8-123 EO-6102-521-000, 1K PUMP BLOCK ASM
WARNING
EO9999-200-003C procedures when you install or remove
EO9999-200-001B EO9999-200-001B components. Otherwise you could
EO9999-200-001E WARNING
equipment.

EO9999-200-003C
EO9999-200-001E
EO9999-200-001B
EO9999-200-001B
EO-4696-521-001 EO9999-200-001K
SEE NOTE 3
EO9999-750-007A
0-1000 PSI SENSOR
4X EO9999-200-003C
4X EO9999-200-005Q
SEE NOTE 2
4X SSHCM006100055G
NOTES:
1. DO NOT OVER TORQUE MICROVALVES (EO-5513-002-000).
DAMAGE TO THE MICROVALVE MAY OCCUR. MAXIMUM
TORQUE IS 45 IN-LBS. MICROVALVE INDICATOR SHOULD BE
FLUSH WITH MICROVALVE CAP WHEN INSTALLED PROPERLY.
USE EO-5513-700-003 (VALVE TOOL) TO INSTALL & REMOVE
MICROVALVES.
2. O-RINGS USED TO CAPTURE THE SOCKET HEAD SCREWS.
3. LUBRICATE O-RING WITH A THIN COAT OF DIELECTRIC
GREASE (EO-4526-050-009) PRIOR TO INSTALLATION.
4. APPLY A THIN COAT OF DIELECTRIC GREASE (EO-4526-050-009) 3X EO-5513-002-000
TO THE VALVE OUTER SURFACE AND THE VALVE SOCKET SEE NOTE 1 Standard Hardware Descriptions
PRIOR TO INSTALLATION FANUC Part No. Description
[EO-6102-521-000] REV B2
1K PUMP BLOCK ASM SHEET 1 OF 1
-292-
8.2.3 Pump QD
The pump quick disconnect for P-700 robots (EO-5093-526-000) attaches to the outer arm of the robot, opposite the pump block. The pump quick disconnect for P-500 robots (EO-4696-526-000) attaches to the outer arm of the robot,
opposite the pump block. The pump quick disconnect ports fluid and pilot lines to the pump block. The pilot lines ported through the pump quick disconnect are pFLUSH, pDUMP, and pDUMP2. The fluid lines ported through the
quick disconnect are PAINT IN, PAINT OUT, PUMP FLUSH, DUMP, DUMP2, and pVENT for P-700 systems. DUMP and DUMP2 use plastic hex fittings (FITCO000001331O) to connect the fluid lines. PAINT OUT, PUMP
FLUSH, and PAINT IN use plastic hex fittings (FITCO000001361O)
Figure 8-124 EO-5093-526-000, 1K Pump W/ Vent QD ASSY
WARNING
WARNING
equipment.

3X FITCO000001332O
EO-5093-526-002 SEE NOTES 1 & 3
2X FITCO000001331O
FITEO000001535O SEE NOTES 1 & 3
4X EO9999-200-001N
4X FITMO000001982O
SEE NOTE 2
FITTO000000788O
B DETAIL B
A 2X DOWLM004000010C
SCALE 2 : 1
SECTION A-A
NOTES:
1. FOLLOW THREAD SEALANT INSTRUCTIONS IN EG-0008 FOR FITTINGS.
2. FITTING COMES WITH COLLET, CARTRIDGE, AND O-RING.
DO NOT USE THE CARTRIDGE AND O-RING.
3. FITTINGS SHOULD BE INSTALLED UNTIL THEY BOTTOM OUT FANUC Part No. Description
ON THE MANIFOLD AS SHOWN
DOWLM004000010C M4 10 LG. Steel Dowl Pin
[EO-5093-526-000] REV B
1K Pump W/ Vent QD ASSY SHEET 1 OF 1
-293-
Figure 8-125 EO-4696-526-000, 3CC Pump
WARNING
WARNING
FITCO000001331O (2) maintenance procedures. Otherwise,
SEE NOTE 1 you could injure personnel or damage
SEE NOTE 3 equipment.
FITEO000001535O
FITCO000001332O REF.
FITMO000001982O (3)
SEE NOTE 2
FITCO000001332O (3)
SEE NOTE 1 DOWLM004000010C (2)
SEE NOTE 3 EO9999-200-001N (3)
A EO-4696-526-001
DETAIL B
SCALE 2 : 1
SECTION A-A
NOTES:
DO NOT USE THE CARTRIDGE AND O-RING.
3. FITTINGS SHOULD BE INSTALLED UNTIL THEY BOTTOM OUT
ON THE MANIFOLD AS SHOWN.
4. FOLLOW INSTRUCTIONS IN EG-00421 FOR SERTO FITTING INSTALLATION. DOWLM004000010C M4 10 LG. Steel Dowl Pin
[EO-4696-526-000] REV B2
SHEET 1 OF 1
-294-
8.2.4 FRA Fast-Flush Regulator

See Color Changer (1K) Section in Chapter 10
8.2.5 Gear Pump

FRA offers 2 pump choices, a 3cc/rev pump (FRA part # EO-4657-511-000 or supplier part # 11-62851-5000-0) and a 6cc/rev pump (FRA part # EO-4657-512-000 / or supplier part # 11-62852-5000-0).
Figure 8-126 EO-4657-511-000 Sheet 1, 3CC GEAR PUMP
WARNING
WARNING
equipment.

5.8
13.3 ROTATION
3.09
11.91
48.0
11.91 3.18
FLUSHING PORT OUT
11.90 3.18
OUTLET PORT
26.19
11.79
64.0
11.79
26.19
0.0000
10.312
- 0.0025
3.18 3.18
INLET PORT FLUSHING PORT IN
13.3
13.49
41.4 NOTE: 13.49

4x 7.14 THRU
1. ZENITH PUMP #11-62851-5000-0

84.1
2. OUTPUT: 3-CC PER REVOLUTION

[EO-4657-511-000] REV B2
3CC GEAR PUMP SHEET 1 OF 2
-295-
Figure 8-127 EO-4657-512-000 Sheet 1 of 2, 6CC GEAR PUMP
WARNING
WARNING
equipment.

5.0
13.3
ROTATION
3.09
11.91
48.0
11.91 3.18
FLUSHING PORT OUT
11.90
3.18
OUTLET PORT
26.19
11.79
64.0
11.79
26.19
0.0000
10.312
- 0.0025
NOTE:
1. ZENITH PUMP #11-62852-5000-0

3.18
INLET PORT
13.3
13.49
3.18
FLUSHING PORT IN
2. OUTPUT: 6-CC PER REVOLUTION
53.9 4x 7.14 THRU

13.49
96.6
[EO-4657-512-000] REV B2
6CC GEAR PUMP SHEET 1 OF 2
The gear pump connects to the pump block with 4 screws (SSHCM006-G). The pump shaft and key align to the pump drive shaft depending on the pump and robot configuration. The drive shaft is held in guided by the pump shaft
retainer. The pump shaft retainer is held in place with two screws (SSHCM006-G).
-296-
Pump Calibration Setup
The calibration settings are found in the IPC Setup menu. To view the calibration settings, use the following procedure:
1. Press MENUS.
2. Select Setup.
3. Press F1, [TYPE].
4. Select pumps.
Two component systems will have setup menus for Pump 1 and Pump 2. One component systems will only show Pump 1.
The screen for a 2k system should look like the following:
PUMP 1 Resin Pump

Size: 6.0cc/rev (check the system documentation for the pump size)
Max Speed: 250rpm
Motor/Pump Reduction: 12:1
PUMP 2 Hardener Pump
Size: 3.0cc/rev (check the system documentation for the pump size)
Max Speed: 250rpm
Motor/Pump Reduction: 10:1
Any changes required as a result of the calibration measurements will be done to the Size section of the screen shown above.
Before starting the pump calibration procedure remove the shaping air ring, and bell cup.
-297-
Pump Calibration Procedure
Tools Required
• Glass beaker— a glass beaker with 2cc graduations is recommended.

• Applicator (spanner) wrench (for removing the shaping air ring).
• Applicator bell cup wrench.
Note Use the procedure to dispense paint manually when you are not in production mode is for calibrating the gear pump with the robot controller. Each gear pump might vary slightly so this should be done each time a pump is replaced.
The calibration should be done periodically to correct for wear over the life of the pump. It is recommended that a log be kept on the line side to record calibration dates, settings, and other system changes. After a pump calibration
number varies by 10% from the original number, it should then be replaced.
1. In Setup –Type IPC, set the cc/rev to 3.06 if using the 3.0cc pump. If using the 6cc pump, set the value to 6.12cc/rev.
2. Position Robot for dispensing fluid.
3. Lockout the robot.
4. From the PW3 Operate Fluid Maintenance screen, select the robot to calibrate.
5. Press MENUS and select Man Functions.
6. Press F1 [TYPE], and select Color Change.
7. Select the Fill Cycle from the Color Change Cycle dropdown menu.
8. Select Start.
9. Position the beaker under fluid nozzle of applicator (bell or gun). This can be held in place by a fixture or by placing the beaker on a flat surface.
10. Unlock and reset the robot.
11. Type the desired flow rate in the flow rate field on the fluid maintenance screen (volume based on beaker size. Example: 100-500cc/min for 60 seconds depending on size of beaker).
Note: The maximum recommended flow rate for Versa Bell is 500cc/min.
Note: It is advised that you use process flowrates used in production for Beakering trials
12. Type the amount of time for the measurement (example 60 seconds) in the test duration field.
13. Select Start Test.
14. Lock out the robot and retrieve the beaker.
15. If the amount of liquid in the beaker is less than expected, decrease the cc/rev value from step 1. Increase the cc/rev setting from step 1 if the amount of liquid in the beaker is greater than expected.
It is recommended that this procedure be repeated before making an actual change. Check the adjusted value. Clean out the lines by selecting Color Change and go to next pump (if the system contains more than one pump). Repeat the
process but select Pump 2 for hardener.
-298-
Figure 8-128 EG-00422 Sheet 1 of 8, Standard Flow Rate Measurement Procedure - Paint
FANUC ROBOTICS ENGINEERING GUIDELINE Page 1 of 8

Title: Standard Flow Rate Measurement Procedure - Paint EG #: EG-00422
Introduction
This document describes two methods for verifying the accuracy of the flow rates delivered by FRA paint robots. ‘Method A’ is a simple volume collection method. ‘Method B’ is a mass collection method that requires more effort, but can achieve greater
accuracy. The accuracy of the measurement method must be considered when verifying the accuracy of the fluid delivery. For example, if the measurement method is accurate to ±0.5% and the accuracy of the flow rate is expected to be ±2.0%, then
measurements of flow rates within ±2.5% are considered acceptable.
Method A – Timed Volume Collection

The timed volume collection method is a quick method of verifying volume flow rates on FRA paint robots. When performed according to this procedure, the timed volume collection method will measure volume flow rates with the accuracies described below.
Table 1: Measurement Uncertainty of Method A

Flow Rate Uncertainty
less than 50 cc/min ± 0.25 cc
at least 50 cc/min but less than 100cc/min ± 0.40 cc
at least 100 cc/min but less than 500cc/min ± 2.00 cc
Required Equipment
• Graduated Glass Cylinder (50 cc, 100 cc or 500 cc)
o ASTM E1272 – 02* Class A, Type I Specifications for Classification, Dimensions, and Tolerances
o The Science Company – Sibata http://secure.sciencecompany.com/
• Serological Pipette, 5cc
o ASTM E 1044** Style 1 Class A specifications for tolerance limitations
o The Science Company – Sibata http://secure.sciencecompany.com/
• Distilled Water
o McMaster-Carr http://www.mcmaster.com/
o #3190K901
Flow Rate Measurement

Caution:
• For transparent liquids, lower meniscus should be read.
• For opaque liquids, upper meniscus should be read.
1. Collect the dispensed liquid in graduated cylinder of appropriate capacity.

2. Note the graduation reading above meniscus position on the graduated cylinder. This is the higher graduation
3. Fill the 5 CC pippet with distilled water.
4. Dispense water from the pippet into the graduated cylinder (water filling up on top of the liquid) till water meniscus touches the noted higher graduation mark.
5. Note the amount of water dispensed from the pippet.
6. Subtract pippet reading from the higher graduation reading = this is the actual amount of liquid originally in the cylinder.
-299-

Table 2: Collected Data Form

Sample No A: Higher B: Pippet =A-B
Graduation Dispense Liquid
Mark (cc) Volume
(cc) (cc)
Example:
Say the liquid level in the 100 cc cylinder falls between 75 cc and 80 cc.
Water is dispensed from the pippet into the cylinder to fill the level up to 80 cc.
Pippet reading is 3.45 cc.
Volume of liquid in the Cylinder = 80 - 3.45 = 76.55 cc
* ASTM E1272 - 02(2007) Standard Specification for Laboratory Glass Graduated Cylinders
** ASTM E1044-96(2001) Standard Specification for Glass Serological Pipets
-300-

Method B – Timed Mass Collection

The timed mass collection method is a high accuracy method of verifying volume flow rates on FRA paint robots. When performed according to this procedure, the timed mass collection method will measure volume flow rates with the accuracies described
below.
Table 3: Measurement Uncertainty of Method B

Flow Rate Relative Uncertainty
greater than 10 cc/min but less than 50 cc/min ±0.5%
at least 50 cc/min but less than 250cc/min ±0.2%
250cc/min or greater ±0.1%
The timed mass collection method has the following steps:

1. Verify pyknometer volume
2. Measure sample density
3. Flow rate measurement
Required Equipment
• Pyknometer
o Paul N. Gardner Company, Inc. 1-800-762-2478
o #WG-SS-83.2 or equivalent
• Electronic scale
o A&D http://www.andweighing.com/
o #GX-2000 or equivalent
• Bomex Beaker (600mL)
o Science Company http://secure.sciencecompany.com/
o #NC-5582 or equivalent
• Partial Immersion Glass Thermometer
o McMaster-Carr http://www.mcmaster.com
o # 38935K19 or equivalent
• A sample (~350cc) of the paint material to be tested
• Solvent for clean-up
• Clean Rags
Fluid Weight Measurement with a Pyknometer

1. Thoroughly clean the pyknometer cup and lid with solvent and dry it with a clean rag.
2. Place the scale on a flat stable surface and ensure that it is level as indicated by the bubble level.
3. Set the units on the scale to grams (g).
4. Re-zero the scale.
5. Gently place the empty pyknometer on the center of the scale and record its weight in the ‘Tare’ column of the data sheet. (Note: a draft, such as the downdraft in a paint booth, will affect the reading of the scale.)
-301-

Figure 1 – Pyknometer on Electronic Scale
6. Fill the cup with the test fluid to within 1mm of the top as shown in Figure 2.
a. If fluid temperature is required, use the glass thermometer to measure the temperature and record it in the data sheet. The thermometer must be inserted nearly to the bottom of the pyknometer for an accurate measurement.
b. If fluid temperature is not required continue to step 7.
Figure 2 – Filled Pyknometer Cup
7. Carefully place the lid on the cup and slowly rotate it while pressing it onto the cup. This will cause excess fluid to escape from the vent hole as shown in Figure 3.
8. Wipe all excess fluid from the lid and exterior of the cup. Any fluid on the exterior will cause an error in the measurement.
-302-

Before Cleaning After Cleaning

Figure 3 – Filled Pyknometer
9. Gently place the filled pyknometer on the center of the scale and record its weight in the ‘Sample’ column of the data sheet.
10. Empty the pyknometer, discarding the sample material.
11. Thoroughly clean the pyknometer cup and lid with solvent and dry it with a clean rag.
Verification of Pyknometer Volume

1. Perform the “Fluid Weight Measurement with a Pyknometer” using water as a test fluid. Record the measurements, including fluid temperature, in Table 4, below.
Table 4: Calibration Data Form

Tare (g) Sample (g) Fluid (g) Temperature (°F)
2. Subtract the weight in grams in the ‘Tare’ column from the weight in grams in the ‘Sample’ column. Record the result in the ‘Fluid’ column.
3. Look up the temperature in Table 5, on the following page. If the weight measured in the ‘Fluid’ column of Table 4 is within the tolerance listed for the corresponding temperature, then the previous cup calibration volume can be used. Otherwise, the
pyknometer must be recalibrated using the ‘Calibration of Pyknometer’ procedure.
-303-

Table 5: Weight Tolerance

Temp (°F) Min (g) Max (g) Temp (°F) Min (g) Max (g)
65 83.63 83.51 73 83.71 83.59
66 83.64 83.52 74 83.72 83.60
67 83.65 83.53 75 83.74 83.62
68 83.66 83.54 76 83.75 83.63
69 83.67 83.55 77 83.76 83.64
70 83.68 83.56 78 83.77 83.65
71 83.69 83.57 79 83.78 83.66
72 83.70 83.58 80 83.80 83.68
Measurement of Sample Density

1. Perform the “Fluid Weight Measurement with a Pyknometer” procedure three times using the fluid that will be dispensed from the robot. Thoroughly cleaning the pyknometer between each sample. Record the measurements in Table 6, below. Fluid
temperature is not required.
2. Calculation of Density
a. For each sample subtract the weight in grams in the ‘Tare’ column from the weight in grams in the ‘Sample’ column. Record the result in the ‘Fluid’ column.
b. Divide the weight in grams in the ‘Fluid’ column by the volume of the cup (included with the cup). Record the result in the ‘Density’ column.
c. Add the three results in the ‘Density’ column and divide the total by 3. Enter the result in the ‘Average Density’ field. The Average Density in grams/cc will be used in the flow tests to convert the collected mass to a volume flow rate.
Table 6: Density Measurement Data Form

Tare (g) Sample (g) Fluid (g) Density (g/cc)
Sample 1
Sample 2
Sample 3
Pyknometer Volume (cc): Average Density (g/cc):
Flow Rate Measurement

A sample data sheet is shown in Table 7.
1. Remove the bell cup from the robot to be tested.
2. Thoroughly clean the beaker with solvent and dry it with a clean rag.
3. Place the scale on a flat stable surface and ensure that it is level as indicated by the bubble level.
4. Set the units on the scale to grams (g).
5. Re-zero the scale.
6. On the data sheet, record the average density of the test fluid as measured by the ‘Measurement of Sample Density’ procedure.
7. Weigh the beaker on the scale and record its weight in the ‘Tare’ row of the data sheet.
8. Place the beaker under the applicator, near the injector tip to avoid splashing.
9. From the Operator Console, initiate a flow test at the flow rate to be tested with 60 second duration. (Note: a shorter duration will decrease the accuracy of the measurement)
10. When the test is complete, weigh the filled beaker on the scale, and record its weight in the ‘Sample’ row under the appropriate flow rate on the data sheet.
11. On the Teach Pendant, press the ‘Status’ button. Select ‘System’. Record the volume dispensed in the last job in the ‘Volume Commanded’ row under the appropriate flow rate on the data sheet.
12. Press F4 [RESTOT] then ‘2. All Equipment’ to reset the totals.
13. Empty the beaker of fluid and ensure that there is no fluid on the exterior or lip of the beaker that could drip.
14. Repeat steps 5 through 13 for the remaining flow rates.
15. Calculation of Error:
a. For each sample subtract the weight in grams in the ‘Tare’ row from the weight in grams in the ‘Sample’ row. Record the result in the ‘Fluid’ row.
b. Divide the weight in grams in the ‘Fluid’ row by the ‘Average Density’ of the fluid. Enter the result in the ‘Volume Dispensed’ row.
c. Subtract the ‘Volume Commanded’ from the ‘Volume Dispensed’. Enter the Result in the ‘Absolute Error’ row under the appropriate flow rate on the data sheet.
d. Divide the ‘Absolute Error’ by the ‘Volume Commanded’ and enter the result in the ‘Relative Error’ row. This is the percentage error in the flow rate.
e. Repeat steps ‘a’ through ‘d’ for all flow rates.
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Table 7: Flow Rate Measurement Data Sheet

Ave. Density = 50 cc/min 100 cc/min 200 cc/min 300 cc/min 400 cc/min 500 cc/min
Tare (g)
Sample (g)
Fluid (g)
Volume Commanded
(cc)
Volume Dispensed (cc)
Absolute Error (cc)
Relative Error (%)
Calibration of Pyknometer
Damage to the pyknometer such as nicks or dents can change the volume that it will hold. The Pyknometer can be recalibrated using the procedure below.
Required Equipment
• Pyknometer to be calibrated
• Electronic scale
o A&D http://www.andweighing.com/
o #GX-2000 or equivalent
• Distilled Water (not deionized, not purified)
o McMaster-Carr http://www.mcmaster.com/
o #3190K901
Calibration Procedure
1. Perform the “Fluid Weight Measurement with a Pyknometer” procedure three times using Distilled Water. Thoroughly dry the pyknometer between each sample. Record the measurements, including fluid temperature, in Table 8, below.
2. Using the measured fluid temperature look up the ‘Distilled Water Density’ in Table 9, below, and record it in the appropriate field in Table 8.
3. Volume Calculation
a. For each sample subtract the weight in grams in the ‘Tare’ column from the weight in grams in the ‘Sample’ column. Record the result in the ‘Fluid’ column.
b. Divide the weight in grams in the ‘Fluid’ column by the ‘Distilled Water Density’. Record the result in the ‘Volume’ column.
c. Add the three results in the ‘Volume’ column and divide the total by 3. Enter the result in the ‘Average Pyknometer Volume’ field. The Average Pyknometer Volume in cc will be used to measure the density of sample materials.
4. Store the Calibration Data Form with the Pyknometer for future reference.
Table 8: Calibration Data Form

Serial No: Tare (g) Sample (g) Fluid (g) Volume (cc)
Sample 1
Sample 2
Sample 3
Distilled Water Density (g/cc): Pyknometer Volume (cc):
Table 9: Density of Distilled Water

Temperature (°F) Density (g/cc) Temperature (°F) Density (g/cc)
65 0.99854 73 0.99759
66 0.99843 74 0.99746
67 0.99832 75 0.99733
68 0.99821 76 0.99719
-305-

69 0.99809 77 0.99705
70 0.99797 78 0.99690
71 0.99785 79 0.99676
72 0.99772 80 0.99661
-306-
8.2.6 2K Specific Hardware

EO-5093-516-000 details the 2K 1+1 manifold assembly for all robot configurations on P-500, P-700, and P-250 robots.
Figure 8-136 EO-5093-516-000 Sheet 1 of 4, 2K 1+1 MANIFOLD ASSEMBLY
WARNING
WARNING
equipment.

ITEM 'A' ITEM 'B' ITEM 'C' ITEM 'D'

FRA PART NO. DESCRIPTION REGULATOR / INLET
SENSOR SUPPLY BLOCK PUMP BLOCK MIX TUBE
EO5093-516-000A 2K 1+1 MANIFOLD - 15PSI FIXED REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC EO5093-516-004A EO5093-516-002A EO5093-516-010A EO-5093-516-011
CAT, RECIRC RES, 150mm MIX ELEM
2K 1+1 MANIFOLD - 30PSI FIXED REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC
EO5093-516-000B CAT, RECIRC RES, 150mm MIX ELEM EO5093-516-004B EO5093-516-002A EO5093-516-010A EO-5093-516-011
EO5093-516-000C 2K 1+1 MANIFOLD - VARIABLE REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC CAT, EO5093-516-004C EO5093-516-002A EO5093-516-010A EO-5093-516-011
RECIRC RES, 150mm MIX ELEM
EO5093-516-000D 2K 1+1 MANIFOLD - 15PSI FIXED REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC EO5093-516-006A EO5093-516-002A EO5093-516-010A EO-5093-516-011
EO5093-516-000E 2K 1+1 MANIFOLD - 30PSI FIXED REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC EO5093-516-006B EO5093-516-002A EO5093-516-010A EO-5093-516-011
2K 1+1 MANIFOLD - VARIABLE REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP, RECIRC
EO5093-516-000F CAT, RECIRC RES, 150mm MIX ELEM EO5093-516-006C EO5093-516-002A EO5093-516-010A EO-5093-516-011
EO5093-516-000G 2K 1+1 MANIFOLD - 15PSI FIXED REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, EO5093-516-004A EO5093-516-002B EO5093-516-010A EO-5093-516-011
NONRECIRC CAT, RECIRC RES, 150mm MIX ELEM
EO5093-516-000H 2K 1+1 MANIFOLD - 30PSI FIXED REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, EO5093-516-004B EO5093-516-002B EO5093-516-010A EO-5093-516-011
EO5093-516-000J 2K 1+1 MANIFOLD - VARIABLE REG, FLOWMETERS, 3cc RES PUMP, 3cc CAT PUMP, NONRECIRC EO5093-516-004C EO5093-516-002B EO5093-516-010A EO-5093-516-011
2K 1+1 MANIFOLD - 15PSI FIXED REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP,
EO5093-516-000K NONRECIRC CAT, RECIRC RES, 150mm MIX ELEM EO5093-516-006A EO5093-516-002B EO5093-516-010A EO-5093-516-011
EO5093-516-000L 2K 1+1 MANIFOLD - 30PSI FIXED REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP, EO5093-516-006B EO5093-516-002B EO5093-516-010A EO-5093-516-011
EO5093-516-000M 2K 1+1 MANIFOLD - VARIABLE REG, PRESS. SENSORS, 3cc RES PUMP, 3cc CAT PUMP, EO5093-516-006C EO5093-516-002B EO5093-516-010A EO-5093-516-011
[EO-5093-516-000] REV *1
2K 1+1 MANIFOLD ASSEMBLY SHEET 1 OF 4
-307-
WARNING
EO-HOSE-011-004 components. Otherwise you could
EO-HOSE-011-004 L=625mm injure personnel or damge equipment
L=300mm
EO-HOSE-011-004
L=700mm WARNING
equipment.

EO-HOSE-011-004
2X EO-9999-500-002 L=700mm
PUMP BLOCK
ITEM 'C'
EO-HOSE-011-004 DUMP BLOCK
L=300mm EO-5093-516-008
REGULATOR/INLET SENSOR BLOCK EO-HOSE-011-004
ITEM 'A' L=550mm SUPPLY BLOCK
ITEM 'B'
EO-HOSE-011-004
L=500mm EO-HOSE-011-004
L=550mm
EO-HOSE-011-004
L=450mm
EO-HOSE-011-004
L=625mm
EO-HOSE-011-004
L=700mm
SEE SHEET 4
EO5093-516-000A SHOWN
[EO-5093-516-000] REV *1
-308-
WARNING
WARNING
equipment.

2X EO-9999-500-002
REF. PUMP BLOCK
ITEM 'C' DUMP BLOCK
REF. EO-5093-516-008
REGULATOR/INLET SENSOR BLOCK SUPPLY BLOCK

ITEM 'A' ITEM 'B'
REF. REF.
SEE SHEET 4
EO5093-516-000D SHOWN
[EO-5093-516-000] REV *1
-309-
WARNING
WARNING
equipment.

MIX TUBE EO9999-200-003I

ITEM 'D'
3X HDWMO000005165O
EO9999-200-003I
FITCO000001488O
[EO-5093-516-000] REV *1
-310-
Figure 8-140 ET-5093-895-002 Sheet 1 of 3, P-700iA 2K 24+3 MANIFOLD MAINTENANCE
WARNING
4X EO9999-200-003G
D procedures when you install or remove
SEE NOTE 8 components. Otherwise you could
C B injure personnel or damge equipment
WARNING
E E Always disconnect power to the robot
equipment.

EO-5513-003-000
DUMP BLOCK VALVE
SEE NOTE 4
PUMP
SEE NOTE 2 C B
SECTION B-B PUMP BLOCK EO-5093-516-014 SUPPLY BLOCK DUMP BLOCK
D
FLOWMETER
SEE NOTE 3
2X EO9999-200-003H REGULATOR/INLET SENSOR BLOCK
FITEO000001660O
TUBEM100000013O
L=30mm
FITCO000001329O
SEE NOTES 6 & 7
A A
SECTION C-C
2X EO-5513-003-000
DUMP BLOCK VALVES
NOTE: SEE NOTE 4
1. FOR REGULATORS MAINTENANCE SEE ET-5093-890-005.

2. FOR PUMPS MAINTENANCE SEE ET-5093-890-007. 6X EO9999-200-003C
3. FOR FLOW METERS MAINTENANCE SEE ET-5093-890-003. 3X FITMO000001982O SEE NOTE 8
SEE NOTE 5 EO9999-200-003I
4. SEE EB-03516 FOR PROPER VALVE INSTALLATION.
DO NOT USE THE CARTRIDGE AND O-RING. 3X HDWMO000005165O
3X EO9999-200-001N
6. COAT NPT WITH TEFLON PASTE.
7. FITTINGS SHOULD BE INSTALLED UNTIL THEY BOTTOM OUT EO-5093-516-011
ON THE MANIFOLD AS SHOWN. MIX TUBE
8. LUBRICATE O-RING WITH A THIN COAT OF DIELECTRIC GREASE FITCO000001488O
(EO-4526-050-009) PRIOR TO INSTALLATION. SEE NOTE 7
EO9999-200-001E
EO9999-200-003I
SECTION E-E FITCO000001488O
2K 24+3 MANIFOLD WITH FLOW METERS

EO5093-517-000A SHOWN SECTION D-D SECTION A-A
[ET-5093-895-002] REV A
P-700iA 2K 24+3 MANIFOLD MAINTENANCESHEET 1 OF 3
-311-
WARNING
2X EO9999-200-001K RESIN EO-5513-003-000 PRESSURE 3X EO-5513-003-000 FITCO000001488O & procedures when you install or remove
PUMP F SEE NOTE 4 SENSOR HARDENER VALVES EO9999-200-001E components. Otherwise you could
SEE NOTE 2 SEE NOTE 4 REF. injure personnel or damge equipment
EO-5513-003-000
H H SOLVAIR VALVES WARNING
SEE NOTE 4 Always disconnect power to the robot
K K equipment.
J J UNLESS OTHERWISE NOTED:
G G
CATALYST PUMP DUMP BLOCK

SEE NOTE 2
PUMP BLOCK F
SECTION F-F EO-5093-516-014 SUPPLY BLOCK
REGULATOR/INLET SENSOR BLOCK
2X FITCO000001488O SEE NOTE 1
SEE NOTE 7
6X FITMO000001982O
SEE NOTE 5
M
6X EO9999-200-001N FITEO000001548O EO-4696-522-000 FITEO000001548O FITCO000001329O
SEE NOTES 6 & 7 SEE NOTE 6 SEE NOTE 6 SEE NOTES 6 & 7
L
2X EO9999-200-001E FITCO000001329O
EO-4696-522-000 SEE NOTES 6, 7 & 11
EXTERNAL CHECK VALVE
SEE NOTES 6 & 9 EO-5513-003-000
SOLVAIR VALVE
2X EO-5513-003-000 SEE NOTE 4
PUMP BLOCK VALVES
SEE NOTE 4
SECTION K-K
2X EO9999-200-001K A A
FITCO000001329O
SEE NOTES 6 & 7
M
L
3X EO9999-200-003C 4X EO9999-200-003C
SECTION G-G 2X VLVCO000000164O
INTERNAL CHECK VALVE
NOTE ORIENTATION
& FLOW DIRECTION
2X FITMO000001982O
SEE NOTE 5
2X EO9999-200-003G
2X EO9999-200-001N SEE NOTE 8
SECTION L-L SECTION M-M

8X EO9999-200-003C
SEE NOTE 8
SECTION J-J 2K 24+3 MANIFOLD WITH PRESSURE SENSORS
SECTION H-H EO5093-517-000D SHOWN
[ET-5093-895-002] REV A
-312-
WARNING
PAINT VALVES - GENERAL MAINTENANCE GUIDLINES WARNING

1. INSPECT ALL PAINT VALVES DURING WEEKLY MAINTENANCE FOR LEAKS AND/OR MALFUNCTION. Always disconnect power to the robot
2. PAINT VALVE IS NOT FIELD SERVICEABLE UNIT. before you perform any service or
3. PAINT VALVE MUST BE REPLACED AS A WHOLE. maintenance procedures. Otherwise,
4. REPLACE A DAMAGED VALVE WITH A NEW VALVE. you could injure personnel or damage
5. DISCARD DAMAGED PAINT VALVES PROMPTLY - DO NOT STORE THEM. equipment.
6. LIFE OF A PAINT VALVE UNDER NORMAL OPERATION IS 2,000,000 (TWO MILLION) CYCLES.
7. LIFE OF A PAINT VALVE USED AS A HARDENER VALVE IS 1,000,000 (ONE MILLION) CYCLES. UNLESS OTHERWISE NOTED:
8. REPLACE PAINT VALVES ACCORDING TO THE FOLLOWING SCHEDULE: SEE EG-00008 FOR LOCTITE REQUIREMENTS
HOSES - GENERAL MAINTENANCE GUIDLINES

1. INSPECT ALL HOSES DURING WEEKLY MAINTENACE.
2. MAKE SURE THAT THERE IS NO FLUID OF ANY KIND IN AIR PILOT HOSES.
3. REPLACE DAMAGED OR FAULTY HOSES AS NEEDED.
4. REPLACE HOSE ALONG WITH FITTINGS AT BOTH ENDS.
5. REPLACE HOSES ACCORDING TO THE FOLLOWING SCHEDULE:
PAINT SUPPLY HOSES - FROM PAINT DROP TO COLOR STACK - ANNUAL
SOLVENT AND AIR SUPPLY HOSES - ANNUAL
PILOT HOSES ON INNER ARM - ANNUAL
WASH LINE - FROM SOLV AIR BLOCK TO PUMP BLOCK - ANNUAL
PAINT-IN LINE - FROM REGULATOR TO PUMP BLOCK - ANNUAL
HOSE BUNDLE - EO-5093-545-000 ASSEMBLY - 6 MONTHS
SERTO FITTINGS AND JOHN GUEST COLLETS

1. INSPECT ALL FITTINGS DURING WEEKLY MAINTENANCE.
2. ALL FITTINGS MUST BE REPLACED AS NEEDED UPON REGULAR INSPECTION.
3. DISCARD THE REPLACED FITTINGS - DO NOT STORE THEM.
OTHER PARTS MAINTENANCE SCHEDULE

1. CHECK VALVES - ANNUAL
2. PRESSURE SENSOR - AS NEEDED
3. 3CC GEAR PUMP - REFER TO GEAR PUMP MAINTENANCE (ET-5093-890-007)
4. MIX TUBE ASSEMBLY - AS NEEDED
[ET-5093-895-002] REV A
-313-
Figure 8-143 ET-5093-895-003, P-700iA 2K FLOW METER MAINTENANCE
WARNING
CLEANING & REPAIR PROCEDURE

WARNING
1. REMOVE THE 4 CORNER HEX BOLTS (1) AND REMOVE THE FLOW METER FROM THE MANIFOLD Always disconnect power to the robot
2. REMOVE THE REMAINING 4 HEX BOLTS (2) WITH A 5MM HEX KEY. before you perform any service or
a. REINSERT 2 OF THE BOLTS YOU JUST REMOVED, THE 2 ON OPPOSITE ENDS WORK BEST, SO THAT you could injure personnel or damage
THEY ARE ONLY HOLDING BY A FEW THREADS. WHILE HOLDING THE UPPER HOUSING FIRMLY, equipment.
TAP THE 2 BOLTS TO SEPARATE THE UPPER AND LOWER HOUSING (3 & 4). DO NOT PRY OR TWIST
THE HOUSINGS TO SEPARATE THEM, AS THIS MAY DAMAGE INTERNAL PARTS OF THE METER.
3. ONCE THE HOUSINGS ARE SEPARATED: UNLESS OTHERWISE NOTED:
a. REMOVE THE GEARS (4) AND SHAFTS (6). LIFT THE GEARS STRAIGHT UP OFF OF THE SHAFTS TO SEE EG-00008 FOR LOCTITE REQUIREMENTS
AVOID DAMAGING THE SHAFTS. SEE EG-00010 FOR TORQUE SPECIFICATIONS
b. CLEAN THE GEARS, SHAFTS, METER BODIES, O-RING GROOVE AND SHAFT HOLES USING SOLVENT
AND A SMALL BRUSH.
c. INSPECT THE GEARS AND SHAFTS. THE GEARS SHOULD SPIN FREELY ON THE SHAFTS.
4. TO REASSEMBLE THE METER:
a. REINSERT THE SHAFTS INTO THE SHAFT HOLES AND REINSERT THE GEARS AS WELL. MAKE SURE
THE GEARS ARE SPINNING FREELY.
b. KEEP THE METER HOUSINGS AS PARALLEL AS POSSIBLE DURING REASSEMBLY. LINE UP THE
INDEX MARKS WHICH ARE LOCATED ON EITHER END OF THE UPPER AND LOWER HOUSINGS.
c. REPLACE THE 4 HEX BOLTS (2) THAT WERE REMOVED LAST AND TIGHTEN THEM TO
APPROXIMATELY 15Nm. DO NOT FORCE THE HOUSINGS TOGETHER AS YOU COULD DAMAGE THE
METER. TIGHTEN THE BOLTS A FEW TURNS AT A TIME, SWITCHING TO ANOTEHR TO GENTLY
SECURE THE HOUSING TOGETHER. OVER TIGHTENING WILL NOT DAMAGE THE METER BUT THE
BOLTS CAN BREAK IF TIGHTENED TOO MUCH.
5. AFTER REASSEMBLY MAKE SURE THE GEARS SPIN FREELY BY GENTLY BLOWING AIR INTO THE
INLET. YOU SHOULD BE ABLE TO HEAR THE GEAR SPIN GIVEN A MODERATE BACKGROUND NOISE
LEVEL.
6. REINSERT THE 4 CORNER HEX BOLTS (1) AND TIGHTEN TO APPROXIMATELY 15Nm.
NOTES:
1. THIS INFORMATION BASED ON AW MAINTENANCE GUIDE

2. FLOW METERS SHOULD TYPICALLY BE DISASSEMBLED, CLEANED, AND INSPECTED AT 6 MONTH
INTERVALS, BUT MAINTENANCE INTERVALS WILL VARY DEPENDING ON PAINT MATERIAL AND DUTY
CYCLE.
3. THE FLOW METERS ARE INDIVIDUALLY CALIBRATED AND SHOULD BE REINSTALLED IN THE SAME
LOCATION FROM WHICH THEY WERE REMOVED.
4. DO NOT INTERCHANGE PARTS BETWEEN FLOW METERS.
[ET-5093-895-003] REV A
P-700iA 2K FLOW METER MAINTENANCE SHEET 1 OF 1
-314-
Inlet Pressure Sensor

Pump inlet pressure is sensed by the pressure sensor mounted prior to the inlet flow meter on the 2K outer arm. The pressure signal is sent to the robot controller via the analog input module in pneumatic control system. The inlet
pressure sensor is used to determine if there is a loss of inlet pressure, and raises an alarm if outside of the working range. The working range for the pressure sensor is between 200 and 1000 counts by default. For 2K systems that
monitor flow versus pressure, there is an option to increase the pump output resolution to 1600 to 8000 counts. The increase in resolution helps to better monitor flow versus pressure.
Inlet Flow Meter

The flow rate is measured by the inlet flow meter mounted upstream of the pump. The flow rate is sent back to the robot controller via the analog input module in the pneumatic control enclosure. Paint Tool compares total flow for a job
measured to the commanded volume of paint. If the total flow is outside of the warning limit or fault limit, either a warning or fault will be posted.
-315-

Figure 8-144 ET-6102-890-006 Sheet 1 of 2, P-500iA 1K PM SCHEDULES
WARNING
PUMP BLOCK procedures when you install or remove
PAINT VALVES components. Otherwise you could
FITCO000001331O injure personnel or damge equipment
10 X 7 SERTO FITTINGS
WARNING
EO-4696-522-000 maintenance procedures. Otherwise,
CHECK VALVES you could injure personnel or damage
equipment.

FITCO000001329O
10 X 7 SERTO FITTINGS
EO5093-503-000C
AIR PILOT REGULATOR
SOLV-AIR BLOCK
PAINT VALVES
1K PUMP BLOCK
SCALE 1:2
COLOR SLICE
PAINT VALVES
FITCO000001329O
10 X 7 SERTO FITTING
FITCO000001332O
FITEO000001526O SERTO FITTING
SERTO FITTING
FITEO000001535O
APPLICATOR
PAINT VALVES
NOTES
1. UNLESS OTHERWISE NOTED, ALL FASTENERS MUST BE TIGHTENED AS
PER TORQUE SPECIFICATIONS IN EG00010.
2. FOLLOW SERTO RECOMMENDED INSTALLATION PROCEDURE FOR PA
FITTINGS TO INSTALL ALL SERTO FITTINGS.
3. ALL FITTINGS MUST BE REPLACED AS NEEDED UPON REGULAR
INSPECTION.
1K PUMP BLOCK QD
VBII 90 DEG APPLICATOR 4. PLEASE REFER TO SHEET 2 FOR MAINTENANCE SCHEDULES.
SCALE 1:2
SCALE 1:5
[ET-6102-890-006] REV B1
P-500iA 1K PM SCHEDULES SHEET 1 OF 2
-316-
Figure 8-145 ET-6102-890-006 Sheet 2 of 2, P-500iA 1K PM SCHEDULES
WARNING
PAINT VALVES - GENERAL MAINTENANCE GUIDLINES procedures when you install or remove
1. INSPECT ALL PAINT VALVES DURING WEEKLY MAINTENANCE FOR LEAKS AND/OR MALFUNCTION. components. Otherwise you could
2. PAINT VALVE IS NOT FIELD SERVICEABLE UNIT. injure personnel or damge equipment
3. PAINT VALVE MUST BE REPLACED AS A WHOLE.
4. REPLACE A DAMAGED VALEVE WITH A NEW VALVE.
5. DISCARD DAMAGED PAINT VALVES PROMPTLY - DO NOT STORE THEM. WARNING
6. LIFE OF A PAINT VALVE UNDER NORMAL OPERATION IS 2,000,000 (TWO MILLION) CYCLES, *SEE NOTE1 Always disconnect power to the robot
7. REPLACE PAINT VALVES ACCORDING TO THE FOLLOWING SCHEDULE: before you perform any service or
equipment.
TABLE 1: 6 BAR AND 10 BAR SYSTEMS (*SEE NOTE 1) UNLESS OTHERWISE NOTED:
PAINT VALVE LOCATION AVG CYCLES PER REPLACE AFTER NO. OF YEARS WITH NO. OF YEARS WITH
JOB HOURS IN USE ONE 10HR SHIFT TWO 10HR SHIFTS
COLOR STACK 1 30,000 10 YRS 2 QTRS 5 YRS 1 QTR

SOLV-AIR BLOCK 2 15,000 5 YRS 1 QTR 2 YRS 2 QTRS
PUMP BLOCK 2 15,000 5 YRS 1 QTR 2 YRS 2 QTRS
APPLICATOR 3 10,000 3 YRS 2 QTRS 1 YR 3 QTR
1. INSPECT ALL HOSES DURING WEEKLY MAINTENANCE.

PAINT SUPPLY HOSES - FROM PAINT DROP TO COLOR STACK - AS NEEDED
SOLVENT AND AIR SUPPLY HOSES - AS NEEDED
PILOT HOSES ON INNER ARM - AS NEEDED
WASH LINE - FROM SOLV AIR BLOCK TO PUMP BLOCK - AS NEEDED
PAINT-IN LINE - FROM REGULATOR TO PUMP BLOCK - AS NEEDED
HOSE BUNDLE - EO-6102-545-000 ASSEMBLY - AS NEEDED
SERTO FITTINGS AND JOHN GUESS COLLETS


4. FIBER OPTIC CABLE FROM J3 HOUSING TO APPLICATOR - ANNUAL
5. HIGH VOTAGE CABLE FROM CASCADE TO APPLICATOR - ANNUAL
NOTES:
1. FOR 5 BAR SYSTEMS: PAINT VALVE LIFE IS REDUCED TO 1,000,000 (1 MILLION) CYCLES. DIVIDE LIFE ESTIMATES IN TABLE 1 BY 2.0
[ET-6102-890-006] REV B1
P-500iA 1K PM SCHEDULES SHEET 2 OF 2
-317-
WARNING
WARNING
4X SSHCM006100020G before you perform any service or
MUST BE IN PLACE maintenance procedures. Otherwise,
PRIOR TO INSTALLATION you could injure personnel or damage
INSTALLED IN ARM
PRIOR TO MATING SCREWS SHOULD BE IN PLACE UNLESS OTHERWISE NOTED:
WITH EO-4696-521-000 AND CAPTURED BY O-RINGS SEE EG-00008 FOR LOCTITE REQUIREMENTS
PRIOR TO INSTALLATION SEE EG-00010 FOR TORQUE SPECIFICATIONS
4X SSHCM006100055S
TORQUE PER EG-0010
(9.2 N-m, 6.8 FT-LB)
EO-4696-512-001 PRIOR TO INSTALLATION
PUMP SHAFT RETAINER
EO-6102-521-000

PUMP - SEE NOTE 2

2X SSHCM006100035G
PUMP DRIVE SHAFT
EXPLODED ISO VIEW

SCALE 1:5
NOTES:
ASSEMBLY NOTES:
1. UNLESS OTHERWISE SPECIFIED TORQUE ALL FASTNERS PER EG-00010.
2. THE FOLLOWING STEPS SHOULD BE FOLLOWED TO INSTALL THE KEY IN 1. INSTALL P/I CABLE (EE-4696-267-002) INTO CORD GRIP (CGRPO000000398O)
THE KEYWAY ON THE PUMP SHAFT.
a. APPLY LOCTITE PRIMER 'N' TO KEY & KEYWAY. WAIT 30 SECONDS. 2. INSTALL PUMP QD ASM (EO4696-526-000) INTO OUTER ARM (EO4696-021-001A)
b. APPLY A SMALL AMOUNT OF LOCTITE 680 TO KEYWAY ON PUMP SHAFT.
CAUTION: PRODUCT CURES QUICKLY 3. INSTALL PUMP DRIVE SHAFT ONTO PUMP MOTOR OUTPUT SHAFT IN OUTER ARM
c. IMMEDIATELY INSTALL KEY IN KEYWAY.
d. IMMEDIATELY WIPE ALL EXCESS LIQUID FROM PUMP SHAFT. 4. INSTALL PUMP SHAFT RETAINER (EO-4696-512-001) AS NOTED INTO OUTER ARM (EO4696-021-001A)
3. PLUG UNUSED RETAINER MOUNTING HOLES
4. CAP PILOT LINES USING CAPMO000000101O FOR STORAGE OF THIS 5. INSTALL GEAR PUMP (EO-4657-511-000) ONTO PUMP MANIFOLD (EO-4696-521-000)
SUBASSEMBLY
6. INSTALL PUMP MANIFOLD (EO-4696-521-000) AND GEAR PUMP (EO-4657-511-000) INTO OUTER ARM (EO4696-021-001A)

[ET-6102-890-007] REV A
-318-
WARNING

WARNING
KEY
PUMP INPUT SHAFT
DYNAMIC SEALS
SEAL PLATE
[ET-6102-890-007] REV A
-319-
Figure 8-148 ET-5093-890-006 Sheet 1 of 2, P700 1K PM SCHEDULES
W A R N IN G
S om e com p o n e nts are h e avy. U se
P 700 1 K P R O C E S S P M S C H E D U L E S
E O -9 9 9 9-1 1 1-1 13 extrem e care a n d fo llow pro p er liftin g
1 0 X 7 P AR K ER FIT TIN G S proce dures w h e n yo u in sta ll o r re m ove
com p o n e nts. O th erw ise yo u co u ld
P U M P B LO C K in jure p erso n n e l o r d am a g e e q uipm e nt
P A IN T V A L V E S
E O -9 9 9 9-1 1 1-1 05
1 0 X 7 P AR K ER FIT TIN G S W A R N IN G
1K - 24 C O LO R S TA C K A lw ays d isco n n ect p ow er to th e ro b ot
b efore yo u p erfo rm a ny service or
P A R K E R F IT T IN G S m a inte n ance proce d ures. O th erw ise ,
yo u co u ld in ju re p erso n n e l or d am a g e
S C A L E 1 :2 .5 e q u ipm e nt.
U N LE S S O TH E R W IS E N O TE D :
S E E E G -0 0 0 0 8 FO R LO C TITE R EQ U IR E M E N TS
E O -9 9 9 9-1 1 1-1 11 S E E E G -0 0 0 1 0 F O R TO R Q U E S P EC IF IC A TIO N S
6 X 4 P A R K E R F IT T IN G
F IT C O 0 0 0 0 0 1 3 31O E O -9 9 9 9-1 15-001

1 0 X 7 S E R T O F IT T IN G S 6M M P A R K E R R IG H T A N G LE A D A P T E R
E O -4 6 9 6-5 2 2-0 0 0
CH ECK VALVES 1K PU M P BLO C K
F IT C O 0 0 0 0 0 1 4 8 8O S C A L E 1 :2
S E R T O F IT TIN G F IT E O 0 0 0 0 0 1 5 35O
F IT C O 0 0 0 0 0 1 3 2 9O S E R T O F IT TIN G
1 0 X 7 S E R T O F IT T IN G S
F IT T O 0 0 0 0 0 0 7 88O
S E R T O F IT T IN G
JO H N G U E S S
C O L LE T S E O 5 0 9 3-5 0 3-0 0 0C F IT C O 0 0 0 0 0 1 3 31O
A IR P ILO T R E G U LA T O R 1 0 X 7 S E R T O F IT T IN G S
S O L V -A IR B L O C K
P A IN T V A L V E S
C O LO R S LIC E
P A IN T V A LV E S F IT C O 0 0 0 0 0 1 3 3 2O
S E R T O F IT TIN G S
1K - 24 C O LO R S TA C K
S E R T O F IT T IN G S F IT E O 0 0 0 0 0 1 5 2 6O
S E R T O F IT T IN G 1K PU M P BLO C K Q D
S C A L E 1 :2 .5 S C A L E 1 :2
NO TES
1. U N LE S S O T H E R W IS E N O T E D , A L L F A S T E N E R S M U S T B E T IG H T E N E D A S
P E R T O R Q U E S P E C IF IC A T IO N S IN E G 0 0 0 1 0.
2. F O L LO W S E R T O R E C O M M E N D E D IN S T A L LA T IO N P R O C E D U R E F O R P A
F IT TIN G S T O IN S T A L L A LL S E R T O F IT T IN G S .
3. A L L F IT TIN G S M U S T B E R E P LA C E D A S N E E D E D U P O N R E G U LA R
IN S P E C T IO N .
4. P LE A S E R E F E R T O S H E E T 2 F O R S P E C IA L M A IN T E N A N C E S C H E D U LE S .
A P P LIC A T O R
P A IN T V A LV E S
V B II 6 0 D E G A P P L IC A T O R
S C A L E 1 :5
[ET-5 0 93-8 9 0-0 0 6] REV A
P -7 0 0 1K P rocess Sch e d ules SHEET 1 OF 2
-320-
Figure 8-149 ET-5093-890-006 Sheet 2 of 2, P700 1K PM SCHEDULES
WARNING
PAINT VALVES - GENERAL MAINTENANCE GUIDLINES injure personnel or damge equipment
1. INSPECT ALL PAINT VALVES DURING WEEKLY MAINTENANCE FOR LEAKS AND/OR MALFUNCTION.
2. PAINT VALVE IS NOT FIELD SERVICEABLE UNIT.
3. PAINT VALVE MUST BE REPLACED AS A WHOLE. WARNING
4. REPLACE A DAMAGED VALEVE WITH A NEW VALVE. Always disconnect power to the robot
5. DISCARD DAMAGED PAINT VALVES PROMPTLY - DO NOT STORE THEM. before you perform any service or
6. LIFE OF A PAINT VALVE UNDER NORMAL OPERATION IS 2,000,000 (TWO MILLION) CYCLES. maintenance procedures. Otherwise,
7. REPLACE PAINT VALVES ACCORDING TO THE FOLLOWING SCHEDULE: you could injure personnel or damage
equipment.

PAINT VALVE REPLACE AFTER NO. OF YEARS WITH NO. OF YEARS WITH SEE EG-00010 FOR TORQUE SPECIFICATIONS
LOCATION AVG CYCLES PER JOB HOURS IN USE ONE 10HR SHIFT TWO 10HR SHIFTS
COLOR STACK 1 30,000 10 YRS 2 QTRS 5 YRS 1 QTR
SOLV-AIR BLOCK 2 15,000 5 YRS 1 QTR 2 YRS 2 QTRS
PUMP BLOCK 2 15,000 5 YRS 1 QTR 2 YRS 2 QTRS
APPLICATOR 3 10,000 3 YRS 2 QTRS 1 YR 3 QTR
1. INSPECT ALL HOSES DURING WEEKLY MAINTENACE.

PAINT SUPPLY HOSES - FROM PAINT DROP TO COLOR STACK - ANNUAL
SOLVENT AND AIR SUPPLY HOSES - ANNUAL
PILOT HOSES ON INNER ARM - ANNUAL
WASH LINE - FROM SOLV AIR BLOCK TO PUMP BLOCK - ANNUAL
PAINT-IN LINE - FROM REGULATOR TO PUMP BLOCK - ANNUAL
HOSE BUNDLE - EO-5093-545-000 ASSEMBLY - 6 MONTHS
SERTO FITTINGS AND JOHN GUESS COLLETS


[ET-5093-890-006] REV A
P700 1K PM SCHEDULES SHEET 2 OF 2
-321-
Figure 8-150 EG-00421 Sheet 1 of 7, Serto PA/PVDF Fitting Installation Instructions
-322-
-323-
-324-
-325-
-326-
-327-
-328-
Figure 8-157 EG-00573 Sheet 1 of 5, Parker Parklok Installation Instructions

Title: ParkLok Installation EG EG #: EG-00573
ParkLok Installation Instructions
The unions are supplied ready for installation
1. Preparation
Clean the tube and cut squarely to length with the Cutty AC 835.
2. Insert fitting base if required

A. If removing thread sealant or other debris, clean plastic components with acetone.
B. If using EO-9999-111-101 or EO-999-111-103 install o-ring to threaded base of fitting as shown below.
Figure 1: O-ring installation position
C. Apply Loctite #7649 Primer N, or ND-611, to both the block and fitting threads.
Primer Directions for Use: Remove dirt, oil and grease. Apply to surfaces to be bonded. Air Dry for several minutes.
D. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the fitting base male threads for both NPT and
BSP threaded fitting bases.
Thread Sealant Directions for Use: Clean and dry parts for best results. Shake well before each use. Remove cap and snip
nozzle tip to desired size. Apply material to parts and assemble. Full cure in 24 hours. Fixture speed with activator <10
minutes.
-329-
Figure 8-158 EG-00573 Sheet 2 of 5 Parker Parklok Installation Instructions

Figure 2: Thread Sealant applied to bottom 3 threads of 8mm WB BSPP fitting base as example.
E. Install fitting base into fluid block using an 11/16” socket.

• 10mmx7mm NPT fitting bases to a torque specification of 4.5Nm using a torque wrench.
• 12mmx9mm & 8mmx6mm BSPP fitting bases will bottom out at the bottom of the hex flange on the top of the
fluid block.
Figure 3: 12mm and 8mm BSPP fittings with O-rings Figure 4: 10mm NPT fitting without O-ring
3. Insert tube
A. Use Tool EO-6246-700-002 to mark the correct depth to install the tube in the fitting. Use a permanent marker to mark
tube. Do not score or scribe.
-330-

4. Install ParkLock fitting sleeve and collet

A. Slide the sleeve/collet combination part (EO-9999-111-00x), as seen in Figure 1, up the tube past the depth mark.
Figure 5: Sleeve/ Collet combination part
B. Push the tube onto the barbed fitting base until the tube is flush with fitting base flange, as shown in Figure 3. When
installing the tube over the barbed fitting, grab the tube no more than 3” away from the trimmed end of the tube.
Figure 6: Proper hose installation on fitting base
C. Slide the sleeve/collet combination part down the tube until it rests of the fitting base flange.
D. IMPORTANT! Verify that the sleeve rests above the collet, and the collet rests on the fitting base flange, as seen in
figure below.
-331-

Figure 7: Proper sleeve collet orientation
E. Using Installation Tool EO-9999-111-701, -702, or -703, press on the top of the fitting sleeve, as shown in Figure 4.
Figure 8: fitting sleeve/collet installation
F. Press firmly until the sleeve rests on the collet flange such that no gap exists at the sleeve/collet seam, as shown in the
figure below.
-332-

Figure 9: Proper ParkLok fitting installation example
• There should be no gap between the sleeve/collet seam if properly installed.

• If a gap is visible, repeat step F until no gap is present.
• A gap of at most 0.5mm is acceptable between the fitting base and collet flange.
5. Uninstallation Procedure
A. Using Sleeve Slitting Tool EO-9999-111-704, -705, or -706, press firmly on the top of the fitting sleeve, as shown in
Figure 6.
Figure 10: ParkLok uninstallation
B. Once the uninstall tool has cut through the sleeve, use the T handle to pull the sleeve and collet off of the barbed fitting
base.
C. Remove the tube from the barbed fitting base.
D. Remove the sleeve and collet from the uninstallation tool using a screwdriver or some other tipped device.
-333-
Figure 8-162 EG-00492, Check Valve Installation Instructions

Title: Check Valve Installation Instructions EG #: 00492
Check Valve Installation Procedure
Introduction:
This procedure describes the proper method for installing and servicing check valve EO-4696-522-000.
Procedure:
1. Prepare the valve in advance by wrapping the male NPT thread (A) with Teflon tape or applying pipe sealant.
2. When installing the check valve, use only the hex (B) closest to the male NPT thread to tighten the component. Important! Using the larger hex on the
cap to tighten the assembly can crack the housing.
3. When installing fittings into the female thread in the check valve, use the larger hex (C) on the cap to keep the check valve from turning. This will
prevent undue stress from being applied to the cap.
-334-
Figure 8-163 EG-00566 Sheet 1 of 2, Released

Title: Pressure Sensor Zero Balance Procedure EG #: EG-00566
Purpose:
Pressure sensor EO9999-750-007A, -007B and -007C may be accurately adjusted to 0 psi when the sensor is at ambient atmospheric pressure conditions. This guideline
described how to adjust the zero balance point and when the procedure is recommended.
Special Tools:
• 2.0 mm or smaller flat blade screwdriver (required to turn adjustment screw), such as 744 – Pocket Mini Screwdriver available from www.generaltools.com.
Establish a zero pressure condition:

Before adjusting the pressure sensor it is necessary to relieve all pressure in the sensor line and verify the reading. This is best accomplished by opening valves to allow
pressure in the system to vent to a dump line. Refer to the following table for advice on which valve to open for this venting. Understand that all systems might not be
represented in the table.
System Description Valves to Open for Zero Pressure Condition Time to allow for
pressure to equalize
P-250iB 1K pDUMP 5 seconds
P-250iB Multiresin 2K For Resin Circuit: pDUMP2, pRES*, pDUMP 25 seconds
For Catalyst Circuit: pCAT*, pDUMP
P-500iA 1K pDUMP 5 seconds
P-500iA Multiresin 2K For Resin Circuit: pDUMP2, pRES*, pDUMP 25 seconds
P-700iA 1K pDUMP 5 seconds
P-700iA Multiresin 2K For Resin Circuit: pDUMP2, pRES*, pDUMP 25 seconds
* pRES and pCAT must be opened using the teach pendant. Use I/O, DIGITAL, OUT and set the corresponding valve to ON.
Read the sensor value:

The raw pressure reading from the sensor is reported in the Analog Input Screen. Choose Menu, I/O, {TYPE], select Analog, and then select AI on the soft key menu
across the bottom of the Teach Pendant screen. The sensor analog input will be either P1OP, P2OP, P1IP, or P2IP, depending on the fluid delivery system and the
pressure sensor under investigation. Verify that the correct AI is being watched for the pressure sensor under investigation. On systems with more than one equipment, be
sure that the sensor on the correct equipment, such as Eq1 and Eq2, has been identified. The unit of measure for the pressure sensor output on the Analog Input screen is
in counts.
Once the zero pressure condition has been established, the teach pendant should report a value between 198 counts psi and 202 counts. A value of 200 counts is equal to
0psi. A small amount of fluctuation might be observed but if all values fall in this range, then the system is normal and no other action is required.
If the reading is greater than 202 counts or less than 198 counts then the sensor should be adjusted.
-335-
Figure 8-164 EG-00566 Sheet 2 of 2, Released

Title: Pressure Sensor Zero Balance Procedure EG #: EG-00566
Adjusting the sensor zero balance:

The sensor should be installed in the block and the retaining nut tightened before adjusting the zero balance. For some assemblies, the block might need to be removed
from the arm in order to access the adjustment area.
To adjust the sensor zero balance:
1. First, establish a zero pressure condition as described in the earlier section.
2. Remove the cover screw using a small flat blade screwdriver. Note: this visible screw is not the adjustment screw. See Figure 1 for an illustration.
3. Insert a flat blade screwdriver (2.0mm or smaller) into the hole from which the cover screw was removed.
4. While reading the teach pendant status screen, gently turn the internal adjustment screw to set the reading to 0 psi. Turning the internal adjustment screw
clockwise will reduce the pressure reading. Turning the screw counter-clockwise will increase the pressure reading. One revolution will change the reading about
4 psi, or 3 counts.
5. When the zero balance has been set, reinstall the cover screw.
cover screw
Figure 1: Location of Cover Screw
-336-
8.4 Troubleshooting
8.4.1 Eq1: PNT1-733 WARN %sPump 1 IN low pressure warning
Cause: Pump #1 inlet pressure has been below the low warning limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• The supply pressure is too low/shutoff.
• The pilot line to resin color valve is removed or broken.
• The resin color valve has failed to actuate
• The supply line (hose, etc.) is removed or broken.
• The resin inlet transducer has failed.
• The inlet regulator has failed.

• Check the pilot line to resin color that is being used.
• Verify that the resin color valve being used is not faulty.
• Make sure the supply pressure is between 90 to 150psi.
• Check the supply line from paint kitchen.
• Check the resin inlet transducer as follows: Through the Analog I/O menu verify the transducer is spanning from near 200 cnts (0 psi) to 600+ cnts (50-80 psi) during a color change cycle.
• Check the inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
8.4.2 Eq1: PNT1-734 PAUS %sPump 1 IN low pressure fault

Cause: Pump #1 inlet pressure has been below the low fault limit for a user configurable period of time. This condition is usually caused by one or more of the following:
Remedy:
• Make sure the supply pressure is between 90 to 150 psi.
-337-
8.4.3 Eq1: PNT1-735 WARN %sPump 1 IN high pressure warning

Cause: Pump #1 inlet pressure has been above the high warning limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• The supply pressure is set too high.
• Check the resin inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
8.4.4 Eq1: PNT1-736 PAUS %sPump 1 IN high pressure fault

Cause: Pump #1 inlet pressure has been above the high fault limit for a user configurable period of time. This condition is usually caused by one or more of the following:
8.4.5 Eq1: PNT1-737 WARN %sPump 1 OUT low pressure warning

Cause: Pump #1 outlet pressure has been below the low warning limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• A broken coupling between the servo motor and pump.
• The resin outlet transducer has failed.
• The injector tip is too large for the paint material being used.
• Broken/Leaking Paint Line
• Verify that the pump is rotating with the motor.
• Check the resin outlet transducer as follows: Through the Analog I/O menu verify the transducer is spanning from near 200 cnts (0 psi) to 260+ cnts (50-80 psi) during a color change cycle.
-338-
8.4.6 Eq1: PNT1-738 PAUS %sPump 1 OUT low pressure fault

Cause: Pump #1 outlet pressure has been below the low fault limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• Check the pilot line to the resin color that is being used.
• Check the supply line from the paint kitchen.
8.4.7 Eq1: PNT1-739 WARN %sPump 1 OUT high pressure warning

Cause: Pump #1 outlet pressure has been above the high warning limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• The problem is usually an obstructed trigger, tower, or paint line.
• The pilot line to mix resin or catalyst valve is removed or broken. (2K only)
• PE or TRIG valve failed to open.
• The mix resin valve has failed. (2K)
• Clogged Mix tube (2K)
• Make sure the lines, trigger, or check valve are not obstructed.
• Check the pilot line to mix resin valve. Verify that the mix resin valve is not faulty.
8.4.8 Eq1: PNT1-740 PAUS %sPump 1 OUT high pressure fault

Cause: Pump #1 outlet pressure has been above the high fault limit for a user configurable period of time. This condition is usually caused by one or more of the following:
• The mix resin valve has failed.
-339-
8.4.9 Eq1: PNT1-744 WARN %sPump 1 motor velocity limit

Cause: The motor velocity for pump #1 has exceeded its operating limit. The motor speed will be reduced to be within operating limit. The motor speed for pump #2 will be reduced to maintain a proper fluid ratio.
Remedy: Lower the flow rate to within the motor limit.
• 750 cc/min for a 3cc/rev pump
8.4.10 Eq1: PNT1-745 WARN %sPump 1 motor servo not ready

Cause: The servo power to pump #1 is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such as E-stop condition or if the controller is machine locked. Correct the condition, and reset the controller.
8.4.11 Eq1: PNT1-746 WARN %sPump 1 totals differ > tolerance

Cause: The actual total flow out of pump #1 as measured by the fluid flow meter has a value that is different than the commanded total flow. This difference is larger than the total flow tolerance.
Remedy:
• Perform a fluid flow test on pump #1 with a beaker and verify that the beaker amount matches the pump #1 size (cc/rev).
• Service the regulator and poppet seat.
• The flow meter could also require cleaning.
• Follow procedure in ET-5093-895-003, located in Figure 8-143.

• The pilot line to hardener color valve is removed or broken.
• The hardener color valve has failed.
• The supply line (hose and so on) is removed or broken.
• The hardener inlet transducer has failed.
Remedy: Perform the following:
• Check the pilot line to verify the hardener color that is being used.
• Verify that the hardener color valve being used is not faulty.
• Make sure the supply pressure is 90 to 150 psi.
• Check the hardener inlet transducer as follows: Through the Analog I/O menu verify the transducer is spanning from near 200 cnts (0 psi) to 260+ cnts (50-80 psi) during a color change cycle.
-340-

• The hardener color valve has failed to actuate
Remedy:
• Check the pilot line to hardener color that is being used.


• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Check the hardener inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.

• The hardener color valve has failed to actuate.
-341-

• A coupling is broken between the servo motor and pump.
• The hardener outlet transducer has failed.
• The injector tip being used is too large.
• Broken or leaking paint line.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the transducer is spanning from near 200 cnts (0 psi) to 260+ cnts (50-80 psi) during a color change cycle.


• The issue is almost always a tower, paint line, or check valve is obstructed.
• The pilot line to mix hardener valve is removed or broken.
• The mix hardener valve has failed. (2K only)
• The injector tip being used is too small. (2K only)
• Check the pilot line to mix hardener valve.
• Verify that the mix hardener valve is not faulty.
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the transducer is spanning from near 200 cnts (0 psi) to 260.+ cnts (50-80 psi) during a color change cycle.
-342-

• The issue is usually a paint line, tower, or check valve is obstructed.
• The mix hardener valve has failed.
• Make sure the lines, trigger or check valve are not obstructed.
8.4.20 Eq1: PNT1-761 WARN %sPump 2 fluid flow rate > set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been continuously greater than a set point window (a percentage) for a user configurable period of time.
• Clean the flow meter using the procedure in ET-5093-895-003, located in Figure 8-143.
8.4.21 Eq1: PNT1-762 WARN %sPump 2 fluid flow rate < set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been continuously less than a set point window (a percentage) for a user configurable period of time.
• Check the operation of the inlet regulator to verify that no "blow by" is occurring across the pump.
• Clean the flow meter using the procedure in ET-5093-895-003, located in Figure 8-143.
8.4.22 Eq1: PNT1-763 WARN %sPump 2 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #2 is detected. This condition is usually caused by one or more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line from paint line to trigger is ok.

• 750 cc/min wit a 3 cc/rev pump
• 1500 cc/min with a 6 cc/rev pump
-343-

Cause: The servo power to pump #2 is not ready. Usually, the servo not ready occurs when servo power is turned off during an E-stop condition, or if the machine is locked.
Remedy: Correct the condition, and reset the controller.

• Verify that pump #2 does not have excessive wear.
8.4.26 Eq1: PNT1-771 WARN %s Res:Hrd ratio is 0.0:0.0

Cause: The color identified in the error message has a default ratio (0.0:0.0) defined. The IPC pumps can only run when a non-zero ratio is defined.
Remedy: Change the default ratio for this color in the SETUP Color DETAIL menu.


• Make sure the supply pressure is between 90 to 150psi.

-344-
Remedy:



• The injector tip is too large for the paint material being used.
-345-



• Check the pilot line to the resin color that is being used.

• The mix resin valve has failed. (2K)
• Clogged Mix tube (2K)
-346-

• The issue usually is an obstructed paint line, tower, or check valve.
• The pilot line to mix resin valve is removed or is broken.
• The mix resin valve has failed.
• The injector tip is too small.
• Check the pilot line to mix resin valve.
• Verify that the mix resin valve is not faulty.
• Check the resin outlet transducer as follows: Through the Analog I/O menu, verify the transducer is spanning from near 200 cnts (0 psi) to 260+ cnts (50-80 psi) during a color change cycle.


Cause: The servo power to pump #1 is not ready.
Remedy: Usually, the servo not ready occurs when servo power is turned off for some reason, such as E-stop condition or if the controller is machine locked. Correct the condition, and reset the controller.

Remedy:
• The flow meter could also require cleaning.
• Follow procedure in ET-5093-895-003.

• The hardener color valve has failed.
-347-

• Check the pilot line to verify the hardener color that is being used.
• Make sure the supply pressure is 90 to 150 psi.

• The hardener color valve has failed to actuate
Remedy:


• Make sure the high pressure fault limit is appropriate.
• Make sure the high pressure sensitivity is appropriate.
• Check the hardener inlet regulator as follows: Through the Analog I/O menu verify the command 200-1000 cnts (0-100 psi) spanning by verifying the output psi at the transducer test port.
-348-

• A coupling is broken between the servo motor and pump.
• Broken or leaking paint line.

-349-

• The issue is almost always a tower, paint line, or check valve is obstructed.
• The mix hardener valve has failed. (2K only)
• The injector tip being used is too small. (2K only)
• Check the hardener outlet transducer as follows: Through the Analog I/O menu, verify the transducer is spanning from near 200 cnts (0 psi) to 260.+ cnts (50-80 psi) during a color change cycle.

• The issue is usually a paint line, tower, or check valve is obstructed.
• The mix hardener valve has failed.
• Make sure the lines, trigger or check valve are not obstructed.
8.4.46 Eq2: PNT1-806 WARN %sPump 2 fluid flow rate > set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been continuously greater than a set point window (a percentage) for a user configurable period of time.
• Clean the flow meter using the procedure in ET-5093-895-003.
8.4.47 Eq2: PNT1-807 WARN %sPump 2 fluid flow rate < set point
Cause: The actual flow rate out of pump #2 as measured by the fluid flow meter has been continuously less than a set point window (a percentage) for a user configurable period of time.
• Clean the flow meter using the procedure in ET-5093-895-003.
-350-
8.4.48 Eq2: PNT1-808 WARN %sPump 2 zero fluid flow rate detected
Cause: Zero fluid flow out of pump #2 is detected. This condition is usually caused by one or more of the following:
• A loose mechanical coupling between the motor and pump.
• A broken line between the pump and trigger.
Remedy: Check the mechanical coupling between the motor and the pump. Make sure the line from paint line to trigger is ok.

• 750 cc/min wit a 3 cc/rev pump
• 1500 cc/min with a 6 cc/rev pump

Cause: The servo power to pump #2 is not ready. Usually, the servo not ready occurs when servo power is turned off during an E-stop condition, or if the machine is locked.
Remedy: Correct the condition, and reset the controller.

• Verify that pump #2 does not have excessive wear.
8.4.52 Eq2: PNT1-816 WARN %s Res:Hrd ratio is 0.0:0.0

Cause: The color identified in the error message has a default ratio (0.0:0.0) defined. The IPC pumps can only run when a non-zero ratio is defined.
Remedy: Change the default ratio for this color in the SETUP Color DETAIL menu.

No special tools.
-351-
-352-
9 Canister Paint Delivery System MARMCP7AP07071E REV. C
9 CANISTER PAINT DELIVERY SYSTEM

9.1 Overview
9.1.1 Introduction
The Canister Paint Delivery System is a metered paint dispensing system that can be electrostatically isolated from the paint supply circuit. This feature allows this system to be used with conductive paint materials such as waterborne
paints while still gaining the benefits of a direct charge system.
The central element of the system is the canister assembly which consists of a piston and sleeve in a housing and a valve manifold for controlling flow of paint and cleaning materials in and out of the canister. The piston and sleeve form
a syringe which can store and dispense a precise quantity of paint. The motion of the piston is controlled by the process axis of the robot. This allows for the dispensed flow rate to be very accurate.
Like all paint delivery systems, the Canister Paint Delivery System is designed to be cleaned and loaded with a new color during Color Change. Electrostatic isolation of the canister is achieved as the last stage of the color change process.
Electrostatic isolation is achieved by emptying and drying the line supplying the canister (called the paint isolation line), the wash line supplying solvent to the applicator and the canister’s dump line.
-353-
MARMCP7AP07071E REV. C 9 Canister Paint Delivery System

The schematic below shows the components of the Canister Paint Delivery System and how they are connected to each other.
Figure 9-1 EG-00390 Sheet 1 of 3, P-700 WB SCHEMATICS

WARNING
MPA10-48 - pC24 4mm extreme care and follow proper lifting
THROUGH INNER ARM WALL MPA10-47 - pC23 4mm procedures when you install or remove
FITCO000001381O (TYP) MPA10-46 - pC22 4mm components. Otherwise you could
MPA10-45 - pC21 4mm CPX/MPA - EO5093-110-001P SHOWN injure personnel or damge equipment
MPA10-44 - pC20 4mm
MPA10-43 - pC19 4mm

MPA10-42 - pC18 4mm
MPA10-48 WARNING
MPA10-41 - pC17 4mm
MPA10-41 before you perform any service or
MPA10-38 - pC14 4mm equipment.
MPA10-33
MPA10-37 - pC13 4mm
MPA10-36 - pC12 4mm
MPA10-34 - pC10 4mm PORT 82/84 MPA10-25 SEE EG-00010 FOR TORQUE SPECIFICATIONS
MPA10-33 - pC9 4mm
SUPPLY PLATE
MPA10-32 - pC8 4mm
MPA10-31 - pC7 4mm
PORT 1
MPA10-30 - pC6 4mm
MPA10-29 - pC5 4mm MPA10-24
MPA10-28 - pC4 4mm MPA10-16
MPA10-27 - pC3 4mm MPA10-17
MPA10-26 - pC2 4mm
MPA10-09
MPA10-25 - pC1 4mm
PORT 1 - 6mm
SUPPLY PLATE
DRY - 4mm MPA10-24 - PLUGGED
MPA10-23 - PLUGGED MPA10-02 MPA10-01
VLVLO000000032O MPA10-22 - PLUGGED
MPA10-21 - PLUGGED
MPA10-20 - pVAIR 4mm MPA10-20 - PLUGGED
MPA10-19 - pVAC 4mm
MPA10-18 - pPI 4mm PORT 3/5 PORT 1
MPA10-17 - pIAIR 4mm
MPA10-16 - p2T 4mm

MPA10-15 - PLUGGED
CPX/MPA
MPA10-14 - pPAINT 4mm


MPA10-11- SEAL 6mm
MPA10-10 - pCAN 4mm

PORT 10 mm
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
10 mm
FITMO000002096O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm
TURB1 10mm
2 I/P G1/4 10 mm
TURBINE 1 10 mm
TDUCO000000004O 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
OUT IN
D/Q -
SA2 10mm
EO-4696-110-008 CPX - 10MM SUPPLY MANIFOLD
BEAR 6mm EO-5093-170-025
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000466O D/Q1 - 10MM
D/Q2 - 10MM
SAS 4mm SAS P/I
[EG-00390] REV F4
P-700 WB SCHEMATICS SHEET 1 OF 3
-354-
WARNING
WARNING
equipment.

ISOCORE DUMP LINES
DUMP2 PAINT
DUMP LINE
DUMP
RECOVERY
CAN
VACUUM EXHAUST
SOL SOL2 PS4 PR4 PS2 PR2
pC4 pC2
PAINT LINE
SOLV/AIR
PAINT ENABLE
pPI pIAIR pPE

pSOL
pTRIG
pSOL2 pIW
VAC INJECTOR
AIR WASH TRIGGER
ISOLATION LINE
pAIR
pCC pBW
p2T
VAIR
BELL WASH
2T
pC3 pC1
PS3 PR3 PS1 PR1
WASH WASH LINE
AIR LINE
[EG-00390] REV F4
-355-
WARNING
WARNING
equipment.

EE-4696
171-00X EE-4696-171-00X
I.S. GROUND 6.9MM
PG9
ETHERNET
SW MEDIA
CONV
COLUMN 1
EE-5093-401-001
JOINT 1 JOINT 2
EE-5093-206-0XX
SEAL
EE-5093-106-00X EE-5093-306-0XX
SEAL
ESTAT
CONTROL
P HH
CASCADE
P
24V EE-5151-014-001
B6 HOUSING
REV B AREA
GROUP C,E,E,F
REF
EE-4560-653-002
JOINT 3
HIGH VOLTAGE CBL
CBLEo000000357o SHAPE AIR CASCADE EE-4696-625-003 QD
P/I 4-20mA
EE-5093-421-001 1ft
X2 X1
AO2
X4 X3
X2 X1 CBLEo000000357o P/I 4-20mA BEARING AIR

X3 BLUE
X4
EE-5093-424-001 1m 4-20mA EE-4696-010 4 BLK EE-4696-020 EE-4560-654-003 DUAL FIBER
AI4 PHOENIX 5
FREQ. XDUCER 6 BRN KEYENCE
8IN/8OUT
526257 EE-4560-
CPX 655-002
EE-5093-411-001
MS
NS
IO
PS
SF
PL
M
COLOR VALVES
KATES CONTROL VALVE

CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00390] REV F4
-356-
Figure 9-4 EG-00403 Sheet 1 of 3, P-500iA WATERBORNE SCHEM
WARNING
THROUGH CARRIAGE CPX/MPA - EO5093-110-001C SHOWN injure personnel or damge equipment
MPA10-40 - pC24 4mm

MPA10-36 - pC20 4mm
equipment.
MPA10-34 - pC18 4mm MPA10-33
MPA10-33 - pC17 4mm
MPA10-30 - pC14 4mm
MPA10-29 - pC13 4mm
MPA10-28 - pC12 4mm
MPA10-27 - pC11 4mm PORT 82/84 MPA10-17
MPA10-26 - pC10 4mm
SUPPLY PLATE
MPA10-25 - pC9 4mm
MPA10-24 - pC8 4mm MPA10-16
MPA10-23 - pC7 4mm
PORT 1
MPA10-22 - pC6 4mm MPA10-09
MPA10-21 - pC5 4mm
MPA10-20 - pC4 4mm MPA10-02

MPA10-19 - pC3 4mm MPA10-01
MPA10-18 - pC2 4mm
MPA10-17 - pC1 4mm
SUPPLY PLATE
PORT 3/5 PORT 1
MPA10-16 - PLUGGED
CPX/MPA
MPA10-14 - pWASH 4mm

MPA10-11- SEAL 6mm
MPA10-10 - pCAN 4mm 10 mm

PORT
PORT
MPA10-07 - pAIR 4mm 82/84
EXHAUST MANIFOLD -
MPA10-06 - pSOL 4mm
CPX - 10MM
FITMO000002095O
MPA10-04 - pIW 4mm
MPA10-03 - pPE 4mm
6 mm
3
TURB2 10mm
2 I/P G1/4
TURB1 10mm
TURBINE 1
TDUCO000000017O-10 BAR 10 mm
EXHAUST TO
6 mm BOOTH
SA1 10mm
TBSP1 - 12MM
TBSP2 - 12MM
SA2 10mm
CARRIAGE ROX
BEAR 6mm

BEAR P/I 8 mm
EO-4696-110-011 OR PROCESS AIR SUPPLY 2 - 12mm
EO-6102-112-001 (5 BAR)
SAS 4mm SAS P/I
SENSO000000466O
BEAR 8mm
[EG-00403] REV C1
P-500iA WATERBORNE SCHEM SHEET 1 OF 3
-357-
WARNING
WARNING
ALTERNATE SOLV/AIR SCHEMATIC FOR maintenance procedures. Otherwise,
SOL2 SINGLE BRANCH BYPASS OPTION you could injure personnel or damage
equipment.
SOL2
SOL
SOLV/AIR
pSOL
pSOL2 pCAN
AIR
ISOCORE DUMP LINE
DUMP
pAIR BARREL
pCC pDUMP
pWASH
2T (WASH) PAINT IN RECOVERY

BARREL
PAINT OUT
BARREL pDUMP2
pDUMP3
CANISTER MANIFOLD
DUMP3
SOL2
SOL PS4 PR4 PS2 PR2

pC4 pC2
PAINT LINE
SOLV/AIR
PAINT ENABLE
pPE
pSOL
pTRIG
pSOL2 pIW
INJECTOR
AIR WASH TRIGGER
ISOLATION LINE
pAIR
pCC pBW
pWASH
BELL WASH
2T (WASH)
pC3 pC1
PS3 PR3 PS1 PR1
WASH WASH LINE
[EG-00403] REV C1
-358-
WARNING
WARNING
equipment.


AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
EE-6102-211-XXX
EE-6102-161-XXX I.S. GROUND

REF
EE-4560-653-00X
JOINT 2 REF
EE-6102-276-XXX HIGH VOLTAGE CBL
EE-4696-625-00X
CBLEo000000366o SHAPE AIR CASCADE QD
P/I 4-20mA
CBLEo000000364o TURBINE SPD

I/P MPPE 4-20mA
X2 X1
AO2
X4 X3
X2 X1 CBLEo000000366o P/I 4-20mA BEARING AIR
REF
X4 X3 24V 9 EE-4696-010 4 BLUE EE-4560-654-00X DUAL FIBER
AI4
EE-5093-424-001 1m 0V 10 PHOENIX 5 BLK EE-4696-020
4-20mA SPD+ 14 FREQ. XDUCER 6 BRN KEYENCE
8IN/8OUT SPD- 16
526257 BELL SPEED, 4-20mA REF EE-4560-

CPX 655-001
EE-5093-411-001
MS PS
NS PL
IO SF
M
COLOR VALVES
COLOR VALVES
KATES CONTROL VALVE

CONTROL VALVE
9 PIN D
CONTROL VALVE
CONTROL VALVE
SHAPING AIR
CONTROLS
[EG-00403] REV C1
-359-
Figure 9-7 EG-00446 Sheet 1 of 3, SMC WB/Single Shape Air Schematics
WARNING
4 mm (plugged @ elbow when fluid reg not used) extreme care and follow proper lifting
S07-40 - pC24 4mm SMC EX600

S07-35 - pC19 4mm
(pc23) equipment.
S07-34 - pC18 4mm S07-34
PORT 1
S07-33 - pC17 4mm (pc18) S07-33
8 MM
SV-12 (8 mm)
SV-32 - pC16 4mm SV-11
(pDump2) Exhaust
SV-02 (8 mm)
SV-30 - pC14 4mm
SV-29 - pC13 4mm
(Brake)
SV-01
SV-27 - pC11 4mm (8 mm)
Exhaust
SV-26 - pC10 4mm (8 mm)
SV-25 - pC9 4mm
SV-24 - pC8 4mm
SV-23 - pC7 4mm
SV-22 - pC6 4mm
SV-21 - pC5 4mm
SV-20 - pC4 4mm

SV-19 - pC3 4mm
SV-16 - PLUGGED
SV-15 - pDUMP3
SV-14 - pWASH
SV-13 - pSOL2
SV-12 - pDUMP2 4mm
SV-11- SEAL 6mm
SV-10 - pCAN 4mm 8mm EXH

PORT
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
LOCAL SUPPLY
EXHAUST MANIFOLD -
FITMO000002095O
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm
SV-01 - pTRIG 4mm
6 mm
10 mm
EXHAUST TO
6 mm BOOTH
3
TURB1 10mm
2 ITV 2050-04F3N4-X69 1
TBSP2 - 12MM
Turbine Air
CARRIAGE ROX
3
SA1 10mm FLOWMETER
ITV 2050-04F3N4-X69 PF2A551-F04-2
2
PSE540
BEAR 6mm BEAR 8mm
[EG-00446] REV C
SMC WB/Single Shape Air Schematics SHEET 1 OF 3
-360-
WARNING
WARNING
equipment.

pCAN
ALTERNATE SOLV/AIR SCHEMATIC FOR
SOL2 SINGLE BRANCH BYPASS OPTION ISOCORE DUMP LINE
SOL2 DUMP
SOL BARREL
pDUMP
SOLV/AIR
PAINT IN RECOVERY
pSOL
BARREL
pSOL2
AIR PAINT OUT

BARREL pDUMP2
CANISTER MANIFOLD
pAIR
pCC
pWASH
2T (WASH)
pDUMP3
DUMP3
SOL2
SOL PS4 PR4 PS2 PR2

pC4 pC2
PAINT LINE
SOLV/AIR
PAINT ENABLE
pPE
pSOL
pTRIG
pSOL2 pIW
INJECTOR
AIR WASH TRIGGER
ISOLATION LINE
pAIR
pCC pBW
pWASH
BELL WASH
2T (WASH)
pC3 pC1
PS3 PR3 PS1 PR1
WASH WASH LINE
[EG-00446] REV C
-361-
WARNING
P500iA FLEX WB WARNING

equipment.

LOW VOLTAGE CABLE
ETHERNET
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
DIVISION 1
GROUP C,D,E,F
JOINT 3
REF
CASCADE
EE-4696-625-00X QD
HIGH VOLTAGE CABLE
REF REF
CABLE INCLUDED ON EE-4696-021 EE-4696-021 DUAL FIBER - EE-4560-655-001 DUAL FIBER - EE-4560-654-00X
KEYENCE
I/P ITV 4-20mA
CBLEO000000384O
CBLEO000000388O Q/I 4-20mA SHAPE AIR 1 FLOW SENSOR
REF

ANALOG I/O COUNTER IN 24 DIGITAL OUT S1
ST PWR PW RV MS NS
0 1 0 1
2 3 2 3 S ET T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
CC VALVES
D-SUB 25 PIN
CC VALVES
SET T ING 3
IN LOW SPEED
D-SUB 25 PIN
0 1 0 1
BUS
IN
2 3 2 3 PCI
OUT HIGH SPEED
CBLEO000000387O
[EG-00446] REV C
-362-
Figure 9-10 EG-00456 Sheet 1 of 3, P-700 SMC WB SCHEMATICS
WARNING
S07-48 - pC24 4mm
S07-47 - pC23 4mm
S07-46 - pC22 4mm components. Otherwise you could
S07-45 - pC21 4mm injure personnel or damge equipment
S07-44 - pC20 4mm
REMOTE
EX600
S07-43 - pC19 4mm
S07-41 - pC17 4mm Always disconnect power to the robot
S07-39 - pC15 4mm S07-34 S07-33 maintenance procedures. Otherwise,
S07-38 - pC14 4mm
8 mm
equipment.
S07-37 - pC13 4mm
FITCO000001381O P1 PORT 3/5 PORT 1
S07-36 - pC12 4mm
THROUGH INNER ARM S07-35 - pC11 4mm UNLESS OTHERWISE NOTED:
WALL S07-34 - pC10 4mm
E 3/5 SEE EG-00008 FOR LOCTITE REQUIREMENTS
S07-33 - pC9 4mm SEE EG-00010 FOR TORQUE SPECIFICATIONS
S07-32 - pC8 4mm PORT 1 PORT 3/5
S07-31 - pC7 4mm P1 PLUGGED PLUGGED
S07-30 - pC6 4mm PLUGGED
S07-29 - pC5 4mm
E 3/5
S07-28 - pC4 4mm PLUGGED
S07-27 - pC3 4mm
S07-26 - pC2 4mm SV-32 SV-31
S07-25 - pC1 4mm
SV-24 - PLUGGED
SV-23 - PLUGGED
SV-22 - PLUGGED
SV-21 - PLUGGED 8 mm 8 mm
SV-20 - pVAIR 4mm FITTING
SV-19 - pVAC 4mm 8 mm SV-02
SV-01
EX600 LOCAL
SV-18 - pPI 4mm
SV-17 - pIAIR 4mm
SV-16 - p2T 4mm
SV-15 - PLUGGED
10 mm
SV-14 - pPAINT
8 mm
SV-13 - pSOL2 4mm E 3/5
SV-12 - pDUMP2 4mm
PORT 1 PORT 3/5
8 mm
SV-11 - SEAL 6mm
SV-10 - pCAN 4mm

SV-09 - pDUMP 4mm
SV-08 - pCC 4mm
SV-07 - pAIR 4mm
EXHAUST MANIFOLD -
SV-06 - pSOL 4mm
FITMO000002096O
P1
SV-04 - pIW 4mm
SV-03 - pPE 4mm
SV-02 - BRAKE 6mm FITTINGS
SV-01 - pTRIG 4mm
DRY 4mm VLVLO000000032O 6 mm
6 mm 6 mm
TURB2 10mm 3 TBSP1 - 10MM

I/P
2 TURBINE 1
TURB1 10mm TDUCO000000019O
TBSP2 - 10MM 10 mm
EXHAUST TO
6 mm 6 mm BOOTH
SA1 10mm 3 12mm

2 I/P SHAPE AIR
CPX - 10MM
SUPPLY MANIFOLD
EO-5093-170-025
BEAR 6mm
CARRIAGE AIR
TBSP1 - 10MM
TBSP2 - 10MM
BEAR P/I 8 mm
SENSO000000473O SA1 - 12MM
SA2 - 12MM
BEAR 8mm
[EG-00456] REV B
P-700 SMC WB SCHEMATICS SHEET 1 OF 3
-363-
WARNING
WARNING
equipment.

ISOCORE DUMP LINES
DUMP2 PAINT
DUMP LINE
DUMP
RECOVERY
CAN
VACUUM EXHAUST
SOL SOL2 PS4 PR4 PS2 PR2
pC4 pC2
PAINT LINE
SOLV/AIR
PAINT ENABLE
pPI pIAIR pPE

pSOL
pTRIG
pSOL2 pIW
VAC INJECTOR
AIR WASH TRIGGER
ISOLATION LINE
pAIR
pCC pBW
p2T
VAIR
BELL WASH
2T
pC3 pC1
PS3 PR3 PS1 PR1
WASH WASH LINE
AIR LINE
[EG-00456] REV B
-364-
WARNING
WARNING
equipment.

INSIDE PAINT BOOTH
EE-6246-207-XXX
LOW VOLTAGE CABLE
CONTROL
LOW VOLTAGE CABLE
EE-6102-271-XXX
I.S. GND
I.S. GROUND
ETHERNET
SW MEDIA
EE-5405-163-003
FIBER ETHERNET
EE-6246-205-XXX
24V POWER
CARRIAGE
ENTRANCE
JOINT 1 JOINT 2
AREA
CLASS 1
24V DIVISION 1
POWER
24V POWER
JOINT 3
CASCADE
EE-4696-625-003 QD
HIGH VOLTAGE CABLE
KEYENCE
CBLEO000000385O
CBLEO000000384O
CBLEO000000388O

4-20mA

ANALOG I/O COUNTER IN 24 DIGITAL OUT S1
ST PWR PWRV MS NS
0 1 0 1
2 3 2 3 SET T ING 1 SET T ING 2
COLOR VALVES
COLOR VALVES
SET T ING 3
CC VALVES
IN LOW SPEED
D-SUB 25 PIN
CC VALVES
D-SUB 25 PIN
0 1 0 1
BUS
IN
2 3 2 3 PCI
OUT HIGH SPEED
CBLEO000000387O
[EG-00456] REV B
-365-
Figure 9-13 DOC-5093-CPDS-Schematic, CANISTER SYSTEM SCHEMATIC
WARNING
WARNING
equipment.

Canister Manifold
Process Motor and Gear Reducer Canister Drive Assembly Canister Assembly Assembly
Paint Line (to Applicator)
Paint Isolation Line Isolation Manfiold Paint Isolation Line

Color Changer
(P-700 Only)
Dump Line (to Dump)
DOC-5093-CPDS-Schematic REV A
CANISTER SYSTEM SCHEMATIC SHEET 1 OF 1
-366-

The following sections describe the installation of the components of the Canister Paint Delivery System and the software setup features that are required for operation.
9.2.1 Canister Drive Assembly

The canister drive assembly (EO-4696-330-000) consists of a precision ball screw (EO-4696-330-003), ram (EO-4696-330-002) and plastic drive bracket (EO-4696-330-001) . It is mounted to the robot arm and driven by the output shaft
of servomotor / gear reducer pair that is mounted in a purged enclosure of the robot. This motor is called the Process Axis Motor. The Process Axis Motor can be commanded automatically by Painttool software to extend and retract the
ram. This is the method that is used to dispense paint and operate the canister system during a production cycle or during color change. The Process Axis Motor can also be commanded to extend or retract the ram using the JOG feature
of the Waterborne SETUP menu on the teach pendant. “Extend” means to move the ram in the paint dispensing direction and “retract” means to move the ram in the opposite direction.
Figure 9-14 EO-4696-330-000, CANISTER DRIVE ASSEMBLY

WARNING
EO4696-330-022 Some components are heavy. Use
INSTALL SO HEAD DOES NOT extreme care and follow proper lifting
EO-4696-330-007 PROTRUED ABOVE SURFACE procedures when you install or remove
WARNING
6X SSHCM005080020S maintenance procedures. Otherwise,
SEE NOTE 4 you could injure personnel or damage
equipment.
EO-4696-330-003 UNLESS OTHERWISE NOTED:

BALLSCREW AND NUT ASSY SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO4696-330-006 2X SSHCM003050010G
EO4696-330-020ATHRU D
SEE NOTE 5
EO 4696-330-021
EO-4696-330-008
NUTLE112032001S
TIGHTEN TO 27N-M [20 FT-LB]
2X BRGBM017040001O ARRANGE "BACK TO BACK"

SEE NOTE 1
2X SEALM215040001O
CANISTER RAM REF.
SSHCM005080016S
SEE NOTES 2,3,4,5
EO 4696-330-002
2X EO 4696-330-010
4X SSHCM008125025G
NOTE 1: PACK BEARINGS and "WELLS" OF NILOS SEALS WITH LG-01-02 GREASE
(HDWMO0000041960) PRIOR TO INSTALLATION
NOTE 2: CROSSTIGHTEN FASTENERS EVENLY TO RETAIN BEARING O.D. TORQUE FASTENERS
TO 5.1 N-M (3.76 FT-LBf).
NOTE 3: HAND TURN TO VERIFY THAT TURNING TORQUE IS EVEN WITH NO BINDING. PEAK TURNING TORQUE = 5.1 IN-LBf (0.576 N-M).
NOTE 4: USE LOCTITE THREADLOCKER 242 (HDWMO000001836O) ON ALL CARBON/STAINLESS STEEL FASTENERS.
NOTE 5: SELECT SHIMS (EO4696-330-000A-D) T0 ACHIEVE 0.076 [0.003] BEARING RETENTION.
EO9999-310-001B REF

EO-4696-330-011 SSHCM005080020S M5 X 0.8 X 20mm LG. Stainless Steel Socket Head Cap
2X SSSMM005080010S SSHCM008125025G M8 X 1.25 X 25mm LG. Glass Filled Nylon Socket Head Cap
EO4696-330-001A
[EO-4696-330-000] REV R2
CANISTER DRIVE ASSEMBLY SHEET 1 OF 1
-367-
Figure 9-15 EO-6102-025-000 Sheet 1 of 2, P-500iA WB OUTER ARM
WARNING
WARNING
equipment.

EO-6102-020-008
FITMO000002005O
SSHCM004070025C
PLGME000000105O
PLGME000000102P
2X SSHCM006100055G
2X HDWMO000003036O
SSHCM008125016S
WSHMM080140160C 6X SSHCM008125030C
GROUND CONNECTION TORQUE TO 16FT-LBS
FACILITY
NOTES:
(9) USE PERMATEX "NO MORE LEAKS" HDWMO000003886O TO PLUG THREADS.
(1) THE (EO-9999-300-005) ASSEMBLY INCLUDES THE FOLLOWING COMPONENTS: Standard Hardware Descriptions
1. (EO-9999-300-006) - MAIN REDUCER BODY (10) PRIME FASTENERS WITH PRIMER N AND USE LOCTITE 222.
2. (EO-9999-300-007) - 112 TOOTH CENTER GEAR
3. (EO-9999-300-008) - 22 TOOTH MOTOR PINION (11) FILL NOTED PORT WITH DIELECTRIC GREASE. SEE (EO-4696-011-000). NUTHM006100000C M6 X 1.0 Steel Hex Nut
4. (BRGBM080100010O) RADIAL BALL BEARING (QTY. 2) NUTHM010125000C M10 X 1.25 Steel Hex Nut
REFER TO THE (EO-9999-300-005) ASSEMBLY DRAWING FOR INSTALLATION (12) LOCTITE 518 CAN BE USED TO HOLD O-RING IN PLACE DURING INSTALLATION PINSM005000016C M5 16 LG. Steel Spirol Pin
INSTRUCTIONS AND TIGHTENING TORQUE INFORMATION. . PINSM005000028C M5 28 LG. Steel Spirol Pin
(13) SEE (EO-6102-512-000) FOR GEAR PUMP ASSEMBLY INSTRUCTIONS. PINSM008000020C M8 20 LG. Steel Spirol Pin
(2) NO ASSEMBLY REAMING NECESSARY. INSERT PIN SO ONLY THE STEEL INSERT IS SFHSM004070012N M4 X 0.7 X 12mm LG. Nylon Slotted Flat Head Screw
CONTACTING THE PIN. THE PIN SHOULD BE RECESSED IN THE FIBERGLASS. (14) USE LOCTITE 416 TO RETAIN PIN EO-4696-330-022: APPLY LOCTITE 770 PRIMER (HDWMO0000060323O) SPHMM006100016N M6 X 1.0 X 16mm LG. Nylon Pan Head Machine Screw
TO THREADED HOLE IN RAM. APPLY 2 DROPS OF LOCTITE 416 (HDWMO000056588O) TO THREADS ON PIN. SSHCM004070025C M4 X 0.7 X 25mm LG. Steel Socket Head Cap
ASSEMBLE IMMEDIATELY.
(3) LUBRICATE ALL O-RINGS WITH VASELINE OR MOLYWHITE PRIOR TO INSTALLATION. SSHCM005080012S M5 X 0.8 X 12mm LG. Stainless Steel Socket Head Cap
(4) TIGHTENING TORQUE FOR MOTOR NUT IS 16.7N-M. USE LOCTITE 242. SSHCM005080025C M5 X 0.8 X 25mm LG. Steel Socket Head Cap
(5) TIGHTEN CENTER TUBE FASTENERS TO 8 N-M. SSHCM006100016C M6 X 1.0 X 16mm LG. Steel Socket Head Cap
(6) SNAP BUTTON (HDWMO000056615O) INCLUDED IN (EO-4696-020-016). SSHCM006100025G M6 X 1.0 X 25mm LG. Glass Filled Nylon Socket Head Cap
SSHCM006100025P M6 X 1.0 X 25mm LG. Plated Steel Socket Head Cap
(7) PRIME ALL STEEL FASTENERS WITH PRIMER N AND USE LOCTITE PER EG-00008 UNLESS OTHERWISE NOTED. SSHCM006100030G M6 X 1.0 X 30mm LG. Glass Filled Nylon Socket Head Cap
DO NOT USE ANY LOCTITE ON PLASTIC FASTENERS. UNLESS OTHERWISE NOTED, TIGHTEN SSHCM006100035G M6 X 1.0 X 35mm LG. Glass Filled Nylon Socket Head Cap
ALL FASTENERS ACCORDING TO EG-00010. SSHCM006100055G M6 X 1.0 X 55mm LG. Glass Filled Nylon Socket Head Cap
(8) REFER TO (ET-6102-800-006) FOR LUBRICATION INSTRUCTIONS. SSHCM008125025C M8 X 1.25 X 25mm LG. Steel Socket Head Cap
ASSEMBLY PART NO. DESCRIPTION A B SSHCM008125030C M8 X 1.25 X 30mm LG. Steel Socket Head Cap
EO6102-025-000A 1400 MM WB OUTER ARM EO4696-021-001B EO5093-020-003B SSHCM010150090C M10 X 1.5 X 90mm LG. Steel Socket Head Cap
EO6102-025-000B 1550 MM WB OUTER ARM EO4696-028-001B EO5093-020-003C
[EO-6102-025-000] REV *4
P-500iA WB OUTER ARM SHEET 1 OF 2
-368-
WARNING
EO-6102-025-001 procedures when you install or remove
EO4696-020-002B injure personnel or damge equipment
2X SSHCM006100025G
EO-4696-515-011 EO9999-200-005E
WARNING
EO-9999-300-005 Always disconnect power to the robot
2X SSHCM005080020G SEE NOTE 1 before you perform any service or
ORIENT LUBE PORT you could injure personnel or damage
ITEM A AS SHOWN (FOR equipment.
MAIN ASSEMBLY BUILD)
EO-4696-310-000 EO9999-200-005B UNLESS OTHERWISE NOTED:
2X PINSM005000016C
2X EO-3461-020-006
4X SSHCM006100025D
ITEM B
4X SSHCM008125025G REF
EO-3461-010-011 EO-5093-540-005
EO-6102-020-004
CGRPO000000002O
2X EO3150-010-006B
EO4696-020-008A
4X SSHCM006100025S
14X SSHCM010150090C
EO-4500-102-008
6X SSHCM006100035S 4X SSHCM006100035G 6X SSHCM006100016C
4X EO-4696-515-005
4X PINSM005000028C - SEE NOTE 2

4X BRGBM015035002O
EO-4696-011-000
EO-3461-010-016
12XSFHSM004070012N
4X SSHCM006100030G
12X SNAPO010000001N
EO-HOSE-011-010 SEE NOTE 6
L=1015mm EO-5093-320-000
PLGME000000105O DRILL 17X 1.6 HOLES THRU
APPROXIMATELY 60MM APART
2X EO9999-320-001A EO-4696-025-003
VLVRO000000010O
SEALE263335001O
6X SSHCM008125030C
AXIS 4
EO-4696-330-022
12X SSHCM005080025C SEE NOTE 14.
SEE NOTE 10 EO-4696-330-000 NOTE: PIN MUST BE INSTALLED SO HEAD IS
AXIS 5 0.1 TO 0.5 MM BELOW SURFACE OF RAM.
EO9999-320-001C
WB
2X CLPME038005038O
2X SSHCM005080012S 2X SPHMM006100016N
2X SSHCM006100012C EO-4696-025-001
2X SSHCM006100016C
2X HDWMO000003036O
4X SSHCM008125025C
2X NUTHM006100000C XGMF-16545
EO9999-200-005D
PLGME062018000P EO-9999-300-008
SEE NOTE 9
NUTHM010125000C - SEE NOTE 4
SSHCM006100010S
HDWMO000003036O
[EO-6102-025-000] REV *4
P-500iA WB OUTER ARM SHEET 2 OF 2
-369-
Figure 9-17 EO-6246-025-000 Sheet 1 of 4, P-700 FLEX WB OUTER ARM ASM

NUTHM006100000C M6 X 1.0 Steel Hex Nut
PINSM005000016C M5 16 LG. Steel Spirol Pin
SHHMM006100020S M6 X 1.0 X 20mm LG. Stainless Steel Hex Head Machine
SSHCM004070025C Screw
SPHMM006100020N M6 X 1.0 X 20mm LG. Nylon Pan Head Machine Screw
SSHCM004070025C M4 X 0.7 X 25mm LG. Steel Socket Head Cap
SSHCM008125016C SSHCM005080010S M5 X 0.8 X 10mm LG. Stainless Steel Socket Head Cap
FITMO000002005O 2X PINSM008000020C
WSHMM080140160C SSHCM005080016C M5 X 0.8 X 16mm LG. Steel Socket Head Cap
GROUND CONNECTION SSHCM005080025C M5 X 0.8 X 25mm LG. Steel Socket Head Cap
FACILITY. NO LOCTITE ON SSHCM006100016C M6 X 1.0 X 16mm LG. Steel Socket Head Cap
THIS SCREW SSHCM006100025G M6 X 1.0 X 25mm LG. Glass Filled Nylon Socket Head Cap
EO-HOSE-011-004 EO5093-020-001B SSHCM006100030S M6 X 1.0 X 30mm LG. Stainless Steel Socket Head Cap
"DRY" L=175mm SSHCM006100035G M6 X 1.0 X 35mm LG. Glass Filled Nylon Socket Head Cap
EO-HOSE-011-010 SSHCM008125010G M8 X 1.25 X 10mm LG. Glass Filled Nylon Socket Head Cap
10x7 BLUE NYLON HOSE FITEO000001652O SSHCM008125016C M8 X 1.25 X 16mm LG. Steel Socket Head Cap
1385mm LG. SSHCM008125025C M8 X 1.25 X 25mm LG. Steel Socket Head Cap
EO6246-020-002A SSHCM008125030G M8 X 1.25 X 30mm LG. Glass Filled Nylon Socket Head Cap
14X Ø1.6mm THRU EO-HOSE-011-010

SEE NOTE 15
PLGME062018000P 2X SSHCM008125010G
VENT PORT - SEE NOTE 9 2X SSHCM006100025G
APPLY SEALANT TO THREAD - 4X SSHCM008125030G
SEE NOTE 10 (6) LOCTITE 518 CAN BE USED TO HOLD O-RING IN PLACE DURING INSTALLATION.
SEE SHEET 2 (7) OPEN
(8) PRIME ALL STEEL FASTENERS WITH PRIMER N AND USE LOCTITE 242 ON ALL STEEL FASTENERS UNLESS OTHERWISE NOTED.
4X SHHMM006100020S DO NOT USE ANY LOCTITE ON PLASTIC FASTENERS. UNLESS OTHERWISE NOTED, TIGHTEN
ALL FASTENERS ACCORDING TO EG-00010.
EO-5093-020-006
APPLY LOCTITE 518 (9) ADD VIGO GREASE P/N XGMF-16156 TO THE FILL PORT UNTIL IT COMES OUT OF THE VENT PORT.
ARM MUST BE VERTICAL WHEN ADDING GREASE. REFER TO OPERATORS MANUAL FOR LUBRICATION INSTRUCTIONS.
NOTES: (10) USE PERMATEX "NO MORE LEAKS" HDWMO000003886O TO PLUG THREADS.
(1) THE EO-9999-300-005 ASSEMBLY INCLUDES THE FOLLOWING COMPONENTS: (11) PRIME FASTENERS WITH PRIMER N AND USE LOCTITE 222.
1. EO-9999-300-006 - MAIN REDUCER BODY
2. EO-9999-300-007 - 112 TOOTH CENTER GEAR (12) SEE EO-5093-011-000 FOR ASSEMBLY INSTRUCTIONS
3. EO-9999-300-008 - 22 TOOTH MOTOR PINION
4. BRGBM080100010O RADIAL BALL BEARING (QTY. 2) (13) DRILL 14 HOLES THRU EO-HOSE-011-010 SPACED APPROXIMATELY 100mm APART AS SHOWN ON SHEETS 1 & 4
PLEASE REFER TO THE EO-9999-300-005 ASSEMBLY DRAWING FOR INSTALLATION
INSTRUCTIONS AND TIGHTENING TORQUE INFORMATION. (14) WHEN USING A BALL NOSE DRIVER SUCH AS EO-4500-705-000 USE REDUCED TORQUE SPEC 4.3 N-m (3.1 ft-lbf)
(2) REFER TO EG-00316 FOR INSTALLATION INSTRUCTIONS. (15) REMOVE AND DISCARD MOTOR PURGE HOLE PLUGS.
(3) NO ASSEMBLY REAMING NECESSARY. INSERT PIN SO ONLY THE STEEL INSERT IS (16) USE LOCTITE 416 TO RETAIN PIN EO-4696-330-022: APPLY LOCTITE 770 PRIMER (HDWMO0000060323O)
CONTACTING THE PIN. THE PIN SHOULD BE RECESSED IN THE FIBERGLASS. TO THREADED HOLE IN RAM. APPLY 2 DROPS OF LOCTITE 416 (HDWMO000056588O) TO THREADS ON PIN.
ASSEMBLE IMMEDIATELY.
(4) LUBRICATE ALL O-RINGS WITH VASELINE OR VIGO GREASE PRIOR TO INSTALLATION.
(17) WRIST DRIVESHAFT & REDUCER MAY BE EITHER KEYED OR SPLINED; VERIFY DRIVESHAFT & REDUCER PART NUMBER
(5) TIGHTENING TORQUE FOR MOTOR NUT IS 16.7N-M, USE LOCTITE 242. ON ACTUAL UNIT PRIOR TO ORDERING REPLACEMENT PARTS
(18) BRUSH SPLINE TEETH ON REDUCER & ON DRIVESHAFT WITH GREASE LG-01-02 AT ASSEMBLY
WARNING WARNING [EO-6246-025-000]

Some components are heavy. Use extreme care and follow proper lifting procedures when Always disconnect power to the robot before you perform any service or maintenance REV D24
you install or remove components. Otherwise you could injure personnel or damge equipment procedures. Otherwise, you could injure personnel or damage equipment.
P-700 FLEX WB OUTER ARM ASM SHEET 1 OF 4
-370-
2X PINSM005000016C
3X SPHMM006100020N
EO-4696-330-000
EO-5093-025-002
6X EO-5093-020-021
EO-5093-025-003
EO-4696-330-022 REF
6X SSHCM006100030S SEE NOTE 16.
USE LOCTITE 222 2X EO-5093-025-004 NOTE: PIN MUST BE INSTALLED SO HEAD IS
TORQUE TO 2 N-M 0.1 TO 0.5MM BELOW SURFACE OF RAM
EO-5093-310-000

-371-
CGRPO000000002O
CORD GRIP
EO-5093-540-007
SPEED SENSE
FIBEROPTIC CONN.
EO-6102-020-008
2X HDWMO000003036O
2X SSHCM006100055G
PLGME000000102P
EO-5093-020-018
EO3150-010-006B
EO-3461-010-016
J5 DRIVE GEAR
3X EO-3461-020-006
EO-5093-020-018 OR
EO5093-020-003A
EO-6102-020-004 SEE NOTE 17 & 18
FIBEROPTIC CONN. COVER
3X EO-5093-020-008
3X EO-5093-020-021
EO-5093-020-018
3X SSHCM006100035S EO3150-010-006C
USE LOCTITE 222 EO3150-010-006B
TORQUE TO 2 N-M
EO-3461-010-011
J4 DRIVE GEAR
6X PINSM005000028C
EO-5093-011-000
WRIST ASSEMBLY
SHOWN IN MASTERING POSITION 6X BRGBM015035002O
SEE NOTE 12
EO-3461-010-017
J6 DRIVE GEAR

-372-
2X NUTHM006100000C 2X SSHCM006100016C
EO-9999-300-005
6X SSHCM006100020C SEE NOTE 1 EO-4696-020-017
2X HDWMO000003036O
EO9999-200-005B 2X SSHCM006100016C
EO9999-200-005E
PLGMM000000026B
BRGBM080100010O REF
SEE NOTE 1
EO-9999-300-007 REF
SEE NOTE 1
BRGBM080100010O REF
SEE NOTE 1
EO-4500-102-008
14X SSHCM010150090C
TORQUE TO 73.5 N-m
EO9999-310-001B
ORIENT AS SHOWN
SEE NOTE 2
PROCESS AXIS MOTOR

BETA 0.5/5000iS #XGMF-15760
ORIENT AS SHOWN
4X SSHCM005080016C 2X CLPME038005038O
TORQUE TO 9.5 N-m 2X SSHCM005080010S
3X SSHCM005080025C
SEE NOTE 16 SEALE263335001O
EO9999-310-008D
ORIENT AS SHOWN 7X SSHCM008125030C
SEE NOTE 2 & 18 14X Ø1.6mm THRU EO-HOSE-011-010
SEE NOTE 15
J5 MOTOR
BETA 1/6000iS #XGMF-18908
ORIENT AS SHOWN
J6 MOTOR
BETA 0.5/5000iS #XGMF-15760 4X SSHCM008125025C
ORIENT AS SHOWN TORQUE TO 32.0 N-m
11X SSHCM005080025C
EO9999-310-008F OR SEE NOTE 16 J3 MOTOR
EO9999-310-001A EO-9999-300-008 REF ALPHA 8/4000iS #XGMF-16545
ORIENT AS SHOWN J3 DRIVE GEAR ORIENT AS SHOWN
EO9999-310-008D
SEE NOTE 2, 17 & 18 ORIENT AS SHOWN SEE NOTE 1
J4 MOTOR SEE NOTE 2 & 18

NUT & LOCK WASHER
BETA 1/6000iS #XGMF-18908 INCLUDED W/ MOTOR
ORIENT AS SHOWN SEE NOTE 5
12X SSHCM005080016C
TORQUE TO 9.5 N-m EO9999-200-005D

you install or remove components. Otherwise you could injure personnel or damge equipment procedures. Otherwise, you could injure personnel or damage equipment. P-700 FLEX WB OUTER ARM ASM SHEET 4 OF 4
-373-
W A R N IN G
S om e com po n e nts are h eavy. U se
1 2X S S H C M 0 0 5 08 0 0 2 5C E O -4 6 96-0 2 5-0 03 extrem e care a n d fo llo w prop er liftin g
S E E N O T E 10 V LV R O 0 00 0 0 0 0 1 0O proce d ures w h e n you in stall o r rem ove
com p o ne nts. O th erw ise yo u co u ld
E O 9 9 99-32 0-0 0 2E E O 4 6 9 6-0 2 0-0 02B IT E M "A ' - S E E T A B LE 2 X P IN S M 0 0 5 0 0 0 0 16C in ju re p erso n n el or dam a ge e qu ipm e nt
E O 9 9 9 9-3 2 0-0 01C 2X S P H M M 0 0 6 1 0 0 0 16N E O -4 6 96-01 1-0 00
B 2X P IN S M 0 0 8 0 00 0 2 0C
4X S S H C M 0 0 8 1 2 5 0 25C
E O -4 6 9 6-0 2 5-0 01 W A R N IN G
A lw ays d isco n n ect p ow er to th e ro b ot
C b efore yo u p erform any service or
C m a inte n a nce proce d ures. O th erw ise,
A XIS 4
yo u co u ld in ju re p erson n e l or dam ag e
e q u ipm e nt.
A A
U NLE S S O T H ER W IS E N O T ED :
WB
S E E E G -0 0 0 0 8 F O R LO C TIT E R E Q U IR E M EN T S
S E E E G -0 0 0 1 0 F O R T O R Q U E S P EC IF IC AT IO N S
A XIS 5
P LG M E 0 6 20 1 8 0 0 0P
SEE NO TE 9
4X S S H C M 0 0 61 0 0 0 3 0G
S S H C M 0 08 1 2 5 0 1 6S C LP M E 0 3 80 0 5 0 3 8O S P H M M 0 0 40 7 0 0 0 6N R E F
W S H M M 0 8 0 1 4 01 6 0C S S H C M 0 0 5 0 80 0 1 2S S E E N O T E 11
G R O U N D C O N N E C T IO N B
F A C ILIT Y
1 2X S F H S M 0 0 4 0 7 00 1 2N
SEE NOTE 6 E O -3 4 6 1-0 1 0-0 16
E O 9 9 9 9-3 20-0 0 2E P LG M E 0 0 0 0 0 0 1 02P
X G M F -1 6 5 45
E O -4 6 9 6-5 1 5-0 11
2X S S H C M 0 0 5 0 8 00 2 0G
E O -61 0 2-0 2 5-0 01
S S H C M 0 0 6 1 0 0 02 5G
E O -6 10 2-0 2 0-0 08
2X S S H C M 0 0 6 1 0 0 0 55G
2X H D W M O 0 0 0 0 0 3 03 6O
N O TES :
(1) T H E (E O -9 9 99-3 00-0 0 5) A S S E M B LY IN CLU D E S T H E FO L LO W IN G C O M PO N E N T S :
1. (E O -9 99 9-30 0-0 0 6) - M A IN R E D U CE R BO D Y (9) U S E P E R M A T E X "N O M O R E LE A K S " H D W M O 0 00 0 0 3 8 8 6O T O P LU G T H R E A D S .
S tanda rd H a rd w a re D e scription s
2. (E O -9 9 9 9-3 0 0-00 7) - 112 TO O TH C EN T E R G EA R (10) P R IM E F A S T E N E R S W IT H P R IM E R N A N D U S E LO C T IT E 2 2 2. F A N U C P a rt N o . D e s c r i p t io n
3. (E O -9 9 9 9-3 0 0-00 8) - 2 2 TO O TH M O TO R P IN IO N
4. (B R G B M 0 8 010 0 010O ) R A D IA L B A LL B EA R IN G (Q TY . 2) N U T H M 006100000 C M 6 X 1 .0 S tee l H e x N u t
R E F ER TO T H E (EO -9 9 9 9-3 0 0-0 0 5) A S S E M BLY D RA W IN G FO R IN S T A L LA T IO N (11) F IL L N O T E D P O R T W IT H D IE LE C T R IC G R E A S E . S E E (E O -4 6 9 6-0 1 1-0 00). N U T H M 010125000 C M 10 X 1 .25 S tee l H e x N u t
IN S T R U CT IO N S A N D T IG H TE N IN G TO R Q U E IN FO R M A T IO N . P IN S M 005000016 C M 5 16 L G . S tee l S p iro l P in
(12) LO C T IT E 5 1 8 C A N B E U S E D T O H O LD O -R IN G IN P LA C E D U R IN G IN S T A L LA T IO N P IN S M 005000028 C M 5 28 L G . S tee l S p iro l P in
(2) N O A S S EM B LY R E A M IN G N E C ES S A R Y . IN S E R T P IN S O O N LY T H E S T E EL IN S E R T IS . P IN S M 008000020 C M 8 20 L G . S tee l S p iro l P in
C O N TA C TIN G TH E PIN . TH E PIN S H O U LD B E R EC E S S E D IN TH E FIB ER G LA S S . (13) S E E (EO -6 1 0 2-5 1 2-0 0 0) F O R G E A R P U M P A S S E M B LY IN S T R U C T IO N S . S F H S M 004070012 N M 4 X 0 .7 X 12 m m L G . N ylon S lo tted F la t H ead S cre w
S P H M M 006100016 N M 6 X 1 .0 X 16 m m L G . N ylon P an H ead M a ch ine S cre w
(3) LU B R IC A T E A L L O -R IN G S W IT H V A S ELIN E O R M O LY W H IT E P R IO R TO IN S T A L LA T IO N . (14) U S E LO C T IT E 4 1 6 T O R E T A IN P IN E O -4 6 9 6-3 30-0 2 2: A P P LY LO C T IT E 7 70 P R IM E R (H D W M O 0 0 0 0 0 6 0 3 23O ) S S H C M 004070025 C M 4 X 0 .7 X 25 m m L G . S tee l S o cke t H e a d C a p
T O T H R E A D E D H O LE IN R A M . A P P LY 2 D R O P S O F L O C T IT E 4 16 (H D W M O 0 0 0 0 5 6 5 88O ) T O T H R E A D S O N P IN . S S H C M 005080012 S M 5 X 0 .8 X 12 m m L G . S ta in le ss S tee l S o cke t H ead C a p
(4) T IG H T E N IN G TO R Q U E FO R M O TO R N U T IS 16.7N -M . U S E LO C TIT E 242. A S S E M B LE IM M E D IA T E LY . S S H C M 005080020 G M 5 X 0 .8 X 20 m m L G . G la ss F illed N ylon S o cke t H ead C a p
S S H C M 005080025 C M 5 X 0 .8 X 25 m m L G . S tee l S o cke t H e a d C a p
(5) T IG H T EN C EN T E R T U B E F A S T E N E R S TO 8 N -M . S S H C M 006100012 S M 6 X 1 .0 X 12 m m L G . S ta in le ss S tee l S o cke t H ead C a p
S S H C M 006100016 C M 6 X 1 .0 X 16 m m L G . S tee l S o cke t H e a d C a p
(6) S N A P B U TTO N (H DW M O 0 0 0 0 5 6615O ) IN C LU D E D IN (E O -46 96-0 2 0-016). S S H C M 006100020 S M 6 X 1 .0 X 20 m m L G . S ta in le ss S tee l S o cke t H ead C a p
S S H C M 006100025 G M 6 X 1 .0 X 25 m m L G . G la ss F illed N ylon S o cke t H ead C a p
(7) P R IM E A LL S T E EL F A S T E N E R S W IT H P R IM E R N A N D U S E LO C T IT E P ER E G -0 0 0 0 8 U N LE S S O TH ER W IS E N O TE D . S S H C M 006100030 G M 6 X 1 .0 X 30 m m L G . G la ss F illed N ylon S o cke t H ead C a p
S S H C M 006100035 G M 6 X 1 .0 X 35 m m L G . G la ss F illed N ylon S o cke t H ead C a p
D O N O T U S E A N Y LO C T IT E O N PLA S T IC F A S T E N ER S . U N LES S O TH E R W IS E N O TED , TIG H T E N
A L L FA S TE N ER S A C C O R D IN G TO E G -0 0010. S S H C M 006100055 G M 6 X 1 .0 X 55 m m L G . G la ss F illed N ylon S o cke t H ead C a p
S S H C M 008125016 S M 8 X 1 .25 X 16 m m L G . S ta in le ss S tee l S o cke t H ead C a p
(8) R E F ER TO (E T -610 2-8 0 0-0 0 6) FO R LU B R IC A T IO N IN S TR U CT IO N S . A SS E M B LY P ART NO. ECN RE V D E S C RIP TION A B S S H C M 008125025 C M 8 X 1 .25 X 25 m m L G . S tee l S o cke t H e ad C a p
S S H C M 008125030 C M 8 X 1 .25 X 30 m m L G . S tee l S o cke t H e ad C a p
E O 6393-025-000A E 120856 A 1400 M M W B O UTE R A RM E O 4696-021-001B E O 5093-020-018B S S H C M 010150090 C M 10 X 1 .5 X 90 m m L G . S tee l S o cke t H e ad C a p
E O 6393-025-000B E 120856 A 1550 M M W B O UTE R A RM E O 4696-028-001B E O 5093-020-018C
[E O -6 3 9 3-0 25-0 0 0] REV A

P-5 0 0iA W B O U T ER A R M SH EET 1 O F 4
-374-
W A R N IN G
E O -4 6 9 6-3 3 0-0 2 2 R E F S om e com p on e nts are h e avy. U se
6X S SH C M 00 8 1 2 5 0 30C S E E N O T E 1 4. extrem e care a n d follow pro p er liftin g
T O R Q U E T O 1 6F T -LB S N O T E : P IN M U S T B E IN S T A L LE D S O H E AD IS 0.1 T O 0.5M M B ELO W S U RF A C E O F R A M . pro ce d ures w h e n yo u in stall or rem ove
com p o ne nts. O th erw ise you co uld
injure p erso n n el or d am a g e e q uipm e nt
W A R N IN G
A lw ays disco n n ect p ow er to th e ro b ot
b efore yo u p erform a ny service or
m ainte n a nce proce d ures. O th erw ise,
yo u co uld in jure perso n n el or d am a g e
e q uipm e nt.
E O -5 09 3-32 0-0 00 U NLE S S O T H ER W IS E N O T ED :

E O -4 69 6-3 3 0-0 00 S E E E G -0 0 0 1 0 F O R T O R Q U E S P EC IF IC AT IO N S
4X E O -4 6 96-5 15-0 05
4X S SH CM 0 0 6 1 0 0 0 35G
E O -4 6 9 6-3 1 0-0 00
4X P IN S M 0 0 5 0 0 0 0 28C - S E E N O T E 2
S E C TIO N A -A 4X B R G B M 0 15 0 3 5 0 02O
2X E O 31 5 0-0 1 0-0 0 6B
E O -34 6 1-0 1 0-0 11
6X S SH C M 0 06 1 0 0 0 16C
1 4X S SH CM 0 1 0 1 5 0 0 90C
D E T A IL E
SCALE 1 : 3
H DW M O 0 00 0 0 3 0 36O
S SH CM 0 0 6 1 0 0 0 12S
2 X IT E M 'B '
2X E O -3 4 6 1-0 2 0-0 06
E O 9 9 9 9-2 0 0-0 05D

6 X S SH CM 0 0 6 1 0 0 03 5G
E O -9 9 99-3 0 0-0 0 8 R E F
N UT H M 0 1 0 12 5 0 0 0C E O 4 6 9 6-0 2 0-0 08A

SEE NO TE 4
F IT M O 0 0 0 0 0 2 0 05O
4X S SH CM 0 0 6 1 0 0 0 20S
S SH CM 0 0 4 0 7 0 02 5C
4X S SH CM 0 0 6 1 0 0 0 25D R E F
S E C TIO N C -C
[E O -6 3 9 3-0 25-0 0 0] REV A

P-5 0 0iA W B O U T ER A R M S H E ET 2 O F 4
-375-
W A R N IN G
S o m e com p o n e nts are h e avy. U se
extrem e care a n d fo llo w pro p er liftin g
pro ce d ures w h e n yo u in stall o r re m ove
E O 9 9 9 9-2 0 0-0 0 5E co m p o n e nts. O th erw ise yo u co uld
S E E NO TE 12 in jure p erso n n el o r d am a g e e q uip m e nt
E O -H O S E -0 1 1-0 10
E O -5 0 9 3-5 4 0-0 07
L= 1 0 1 5m m W A R N IN G
E O -6 1 0 2-0 2 0-0 04 E O 9 9 9 9-2 0 0-0 0 5B D R IL L 1 7X 1 .6 H O L E S T H R U A lw a ys d isco n n ect p ow e r to th e ro b ot
J A P PR O X IM A T E LY 6 0M M A P AR T b efo re yo u p erfo rm a ny se rvice o r
C G R P O 0 0 0 0 0 0 0 0 2O m ainte n a nce p ro ce d ure s. O th erw ise ,
P LG M E 0 0 0 0 0 0 1 0 5O yo u co uld inju re p erso n n el o r d am a g e
e q uip m e nt.
C LP M E 0 3 8 0 0 5 0 3 8O
U NLE S S O TH ER W IS E N O TE D :
S SH CM 0 0 5 0 8 0 0 1 2S
S E E E G -0 0 0 0 8 FO R LO C T ITE R EQ U IR EM EN TS
S E E E G -0 0 0 1 0 FO R T O R Q U E S P EC IFIC ATIO N S
E O -4 5 0 0-1 0 2-0 08
2X H D W M O 0 0 0 0 0 3 0 3 6O
2X S SH C M 0 0 6 1 0 0 0 1 6C
2X N U T H M 0 0 6 1 0 0 0 0 0C
E O -9 9 9 9-3 0 0-0 05
SEE NOTE 1
2 X B R G B M 0 8 0 1 0 0 0 1 0O R E F J E O -4 6 9 6-0 2 0-0 17
SEE NOTE 1 2 X S SH C M 0 0 6 1 0 0 0 1 6C
E O -9 9 9 9-3 0 0-0 0 7 R E F S E ALE 2 6 3 3 3 5 0 0 1O
SEE NOTE 1
S E C TIO N B -B
S E C TIO N J-J
[EO -6 3 9 3-0 2 5-0 0 0] REV A

P-5 0 0iA W B O U T ER AR M S H E ET 3 O F 4
-376-
W A R N IN G
S o m e com p o n e nts are h e avy. U se
extrem e care a n d fo llo w pro p er liftin g
E O -6 1 0 2-0 2 5-0 01 pro ce d ures w h e n yo u in stall o r re m ove
E O 4 6 9 6-0 2 0-0 0 2B R E F . co m p o n e nts. O th erw ise yo u co uld
2 X S SH C M 0 0 6 1 0 0 0 2 5G in jure p erso n n el o r d am a g e e q uip m e nt
E O -4 6 9 6-5 1 5-0 11
2 X S SH C M 0 0 5 0 8 0 0 2 0G W A R N IN G
E O 9 9 9 9-2 0 0-0 0 5E R E F . A lw a ys d isco n n ect p ow e r to th e ro b ot
O R IE N T LU B E P O R T b efo re yo u p erfo rm a ny se rvice o r
IT E M A R E F . A S S H O W N (F O R m ainte n a nce p ro ce d ure s. O th erw ise ,
M A IN A S S EM B L Y B U IL D ) yo u co uld inju re p erso n n el o r d am a g e
e q uip m e nt.
E O 9 9 9 9-2 0 0-0 0 5B R E F .
2X P IN S M 0 0 5 0 0 0 0 1 6C R E F . S E E E G -0 0 0 0 8 FO R LO C T ITE R EQ U IR EM EN TS
2X E O -3 4 6 1-0 2 0-0 06
IT E M B R E F . 4 X S SH C M 0 0 8 1 2 5 0 2 5G R E F
E O -3 4 6 1-0 1 0-0 1 1 R E F . E O -5 0 9 3-5 4 0-0 0 5 R E F .
E O -6 1 0 2-0 2 0-0 0 4 R E F .
C G R P O 0 0 0 0 0 0 0 0 2O R E F .
2 X E O 3 1 5 0-0 1 0-0 0 6B R E F .
E O 4 6 9 6-0 2 0-0 0 8A R E F .
4 X S SH CM 0 0 6 1 0 0 0 2 5P R E F .
1 4X S SH C M 0 1 0 1 5 0 0 9 0C R E F .
E O -4 5 0 0-1 0 2-0 0 8 R E F .
6 X S SH C M 0 0 6 1 0 0 0 3 5S R E F . 4 X S SH C M 0 0 6 1 0 0 0 3 5G 6X S SH CM 0 0 6 1 0 0 0 1 6C R E F
4 X E O -4 6 9 6-5 1 5-0 05
2X P IN S M 0 0 5 0 0 0 0 2 8C R E F . 4 X S SH CM 0 0 6 1 0 0 0 3 0G R E F .
E O -4 6 9 6-0 1 1-0 0 0 R E F .
4 X B R G B M 0 1 5 0 3 5 0 0 2O R E F .
E O -3 4 6 1-0 1 0-0 1 6 R E F .
S F H S M 0 0 4 0 7 0 0 1 2N R E F .
S N A PO 0 1 0 0 0 0 0 0 1N R E F .
P L G M E 0 0 0 0 0 0 1 0 5O
2 X E O 9 9 9 9-3 2 0-0 0 2E R E F .
E O -4 6 9 6-0 2 5-0 03
V L V R O 0 0 0 0 0 0 0 1 0O
6X S SH CM 0 0 8 1 2 5 0 3 0C R E F .
4 X S SH C M 0 0 5 0 8 0 0 2 5C R E F .
E O 9 9 9 9-3 2 0-0 0 1C R E F .
2 X S PH M M 0 0 6 1 0 0 0 1 6N
2 X S SH CM 0 0 6 1 0 0 0 1 2C R E F . E O -4 6 9 6-0 2 5-0 01
2X S SH CM 0 0 6 1 0 0 0 1 6C R E F .
2 X H D W M O 0 0 0 0 0 3 0 3 6O R E F .
4X S SH CM 0 0 8 1 2 5 0 2 5C R E F .
2 X N U T H M 0 0 6 1 0 0 0 0 0C R E F . X G M F -1 6 5 4 5 R E F .
E O 9 9 9 9-2 0 0-0 0 5D R E F .
P L G M E 0 6 2 0 1 8 0 0 0P E O -9 9 9 9-3 0 0-0 0 8 R E F .
N U T H M 0 1 0 1 2 5 0 0 0C R E F .
S SH CM 0 0 6 1 0 0 0 1 0S R E F .
H DW M O 0 0 0 0 0 3 0 3 6O R E F .
[EO -6 3 9 3-0 2 5-0 0 0] REV A

P-5 0 0iA W B O U T ER AR M S H E ET 4 O F 4
-377-
Installation
The canister drive assembly (EO-4696-330-000) is mounted to the arm with 4 M8 glass-filled nylon socket head screws. Between each pair of mounting screws is a special 10mm pull dowel (EO-4696-310-010). These pins locate the
canister drive bracket precisely, relative to the robot arm.
Some robot models have 2 additional M8 x 10mm glass-filled nylon screws located in-line with the two special pull dowels. These screws fasten alignment plates and should not be removed.
To install the canister drive assembly, look inside the canister compartment toward the FRP, located at the inner arm and outer arm joint, and note the orientation of the key on the output shaft of the process axis output shaft. Arrange the
keyway on the flexible coupling on the canister drive assembly so that it will mate with the key when installed in the arm. Carefully align the coupling and the output shaft so that the key and keyway engage.
Next, loosely install one of the 4 M8 mounting screws through the arm to engage the corresponding threaded holes on the drive bracket. Check the alignment of the other 3 holes and when in position, loosely install the 3 remaining M8
mounting screws. The drive bracket should be loose enough to allow for easy insertion of the special 10mm pull dowels. Engage the special 10mm pull dowels. Tighten the 4 mounting screws to 32 Nm torque. Complete the installation
by gently tapping in the special 10mm pull dowels until they are flush with the surface of the arm.
9.2.2 Canister Assembly

The canister assembly (EO-5093-320-000), includes the piston (EO-4696-320-017), canister sleeve (EO4696-320-020C), canister body (EO-4696-320-001), manifold retainer nut (EO-4696-320-009), and an integrated tool (EO-4696-
320-018). The piston connects to the ram in the canister drive assembly with a special metal pin (EO-4696-320-022). The canister body connects to the plastic drive bracket of the canister drive assembly with a manifold retainer nut. A
tool to engage the manifold retainer nut is built onto the canister assembly. It has a set screw that holds it in place for storage. To use the tool for installation or removal, loosen the set screw to free the tool and insert a suitable hand tool
into the 9mm hole (an 8mm Allen wrench, for example) in the integrated tool to turn it. By engaging the tabs the tool can be used as a wrench.
-378-
Figure 9-25 EO-5093-320-000, CANISTER ASSEMBLY
WARNING
WARNING
equipment.

SEALM000000005O 2X EO-4696-320-018
RETAINER REMOVAL TOOL
LOOSEN PAN HEAD SCREW
EO-4696-320-005 ENGAGE TABS
ROTATE WITH SCREWDRIVER OR ROD IN HOLE EO9999-200-004J
EO-4696-320-001
EO-4696-320-016 EO4696-320-020C
EO-4696-320-017
SPHMM006100016N 2X EO-4696-320-009
SEE NOTES 2,7
NOTE 1: APPLY A LAYER OF DIELECTRIC GREASE TO THE SLEEVE OD PRIOR TO INSTALLATION INTO CANISTER.
NOTE 2: APPLY A LAYER OF DIELECTRIC GREASE (EO-4526-050-009) TO THREADS PRIOR TO ASSEMBLY.
NOTE 3: DIRT AND CONTAMINATION TRAPPED IN PISTON/SLEEVE CAN LEAD TO PREMATURE WEAR AND PISTON
SEAL FAILURE. CLEAN PISTON (EO-4696-320-017) and SLEEVE (EO4696-320-020C) WITH HENKEL/LOCTITE
NATUAL BLUE CLEANER (#82253) AND A CLEAN LINT FREE CLOTH PRIOR TO INSTALLATION.
NOTE 4: USE EO-4696-700-035 PISTON INSTALL TOOL TO LOAD PISTON INTO CYLINDER Standard Hardware Descriptions
NOTE 7: TORQUE RETAINING NUT TO 33.9 N-M (25 FT-LBf). SPHMM006100016N M6 X 1.0 X 16mm LG. Nylon Pan Head Machine Screw
[EO-5093-320-000] REV B3
CANISTER ASSEMBLY SHEET 1 OF 1
-379-
Installation
Prepare to install the canister assembly (EO-5093-320-000) by moving the piston to the top of the canister body so that the stem of the piston is visible. Gently use a small screwdriver in the connection pin hole to adjust the orientation of
the piston so that the hole in the piston will align with the hole in the ram when assembled. Use the JOG feature in the SETUP / WB screen on the Teach Pendant to retract the ram so that the hole in the ram is accessible and not beyond
the end of the drive bracket.
Apply Loctite Primer 770 (HDWMO000060323) to the threaded hole in the ram.
Move the canister assembly into position and insert the end of the piston into the ram. Apply 2 drops of Loctite 416 (HDWMO000056588) on the threads of the pin for retention. Align the holes and insert the metal pin (EO-4696-330-
022). Use a small screwdriver to complete the installation of the pin. The pin is properly installed when the surface of the head of the pin is below the surface of the ram, but not deeper than 0.5 mm. If the pin is installed incorrectly it
will damage the seal on the top of the canister and lead to canister torque alarms.
Complete the installation by installing tightening the manifold retainer nut onto the canister drive bracket. Take care to engage the manifold retainer nut threads properly. It should turn on easily. Tighten the nut until it stops. The gap
between the edge of the manifold retainer nut and the canister drive bracket should be approximately 1mm.
9.2.3 Canister Manifold Assembly
The canister manifold assembly, EO-5093-310-000 for P700 and P250 and EO-4696-310-000 for P500, contains the control valves and hose connections for the canister system. It connects to the canister assembly with a manifold
retainer nut (EO-4696-320-009). A tool (EO-4696-320-018) to engage the manifold retainer nut is built onto the canister assembly. It has a set screw that holds it in place for storage. To use the tool for installation or removal, loosen the
set screw to free the tool and insert a suitable hand tool into the 9mm hole (an 8mm Allen wrench, for example) in the integrated tool to turn it. By engaging the tabs the tool can be used as a wrench.
-380-
Figure 9-26 EO-4696-310-000, CANISTER MANIFOLD
WARNING
7X SSHCM006100040G
WARNING
equipment.
3X EO9999-200-001U
EO9999-200-005X SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO-4696-560-012
EO9999-200-001E
EO9999-200-003D
SEE NOTE 1 7X EO-5513-003-000
EO9999-200-001K
EO-4696-310-002
3X EO9999-200-001N
3X FITMO000001982O
EO9999-200-001W
EO-4696-310-029
EO-4696-310-031 2 X EO9999-200-001E
EO9999-200-001F EO9999-200-003I
EO9999-200-001E SEE NOTE 1
EO9999-200-003I
SEE NOTE 1
PAINT IN -REF EO9999-200-005AD

6 MM ID X 8 MM OD FEP
WITH 3/8" ID X 5/8" OD VITON JACKET
NOTE1: APPLY THIN LAYER OF DIELECTRIC GREASE
(EO-4526-050-009) IN "POCKETS" FOR BARRELS
(PAINT IN, DUMP, PAINT OUT) AND INTERFACE BETWEEN
EO-4696-310-001/EO-4696-310-002
[EO-4696-310-000] REV W1
CANISTER MANIFOLD SHEET 1 OF 1
-381-
Figure 9-27 EO-5093-310-000, CANISTER MANIFOLD ASM
WARNING
WARNING
equipment.

FITEO000001664O
TUBEM060000017O
L=30mm
2X SSHCM006100016S
FITCO000001488O
2X EO-5093-310-003
EO9999-200-003I
EO-5093-310-002
EO-5093-320-000

[EO-5093-310-000] REV F2
CANISTER MANIFOLD ASM SHEET 1 OF 1
-382-
Figure 9-28 EO-5093-310-002, CANISTER MANIFOLD ASM
WARNING
WARNING
equipment.

2X EO9999-200-003I
4X FITMO000001982O
SEE NOTE 1
4X EO9999-200-001N WHITE O-RING

DO NOT USE O-RING SUPPLIED WITH FITTING
4X EO-5513-003-000
EO-5093-310-001
NOTES:
1. FITMO000001982 IS JOHN GUEST PART #MM2804N WHICH INCLUDES
THE 4MM COLLET, BRASS BODY AND O-RING. DISCARD BRASS BODY
AND O-RING.
[EO-5093-310-002] REV B1
CANISTER MANIFOLD ASM SHEET 1 OF 1
-383-
Figure 9-29 EO-6263-310-002, 3 WAY MANIFOLD
WARNING
SSHCM006100016S
WARNING
equipment.

(EO-4696-310-039)
(2X EO9999-200-001F)
(2X EO9999-200-001E)
EO9999-200-003I
SEE NOTE 1
3X SSHCM006100016S
EO9999-200-001K EO-5093-310-015
3X FITCO000001329O
SEE NOTE 2
SEE NOTE 1
NOTE:
1. COVER HOLE WITH ADHESIVE TAPE
TO RETAIN SEAL (EO9999-200-003I) Standard Hardware Descriptions
2. FOLLOW THREAD SEALANT INSTRUCTIONS IN EG-00008. FANUC Part No. Description
[EO-6263-310-002] REV A
3 WAY MANIFOLD SHEET 1 OF 1
-384-
Installation
It is best to install the canister manifold assembly (EO-5093-310-002) to the canister assembly before the canister assembly is installed in the arm.
Prepare to install the canister manifold assembly onto the canister assembly by lubricating the static o-ring (EO9999-200-004J for WB systems or EO-5093-320-100 for SB systems) with dielectric grease (EO-4526-050-009) and placing
it on the outer diameter of the exposed canister sleeve. Lubricate the threads of manifold retaining nut with dielectric grease.
Insert the canister sleeve and static o-ring into the corresponding pocket on the canister manifold.
Complete the installation by installing tightening the manifold retainer nut onto the canister manifold. Take care to engage the manifold retainer nut threads properly. It should turn on easily. Tighten the nut until it stops. The gap between
the edge of the manifold retainer nut and the canister manifold should be approximately 4 mm.
9.2.4 Paint Supply Components

The tubing and fittings are called “the isolation line”, which connect the color stack to the canister manifold. This passage is cleaned of paint and dried with compressed air during the “FILL” color change cycle in order to establish
electrostatic isolation. The internal volumes of this passage, together with the internal volume of the central passage of the color changer, form the “isolation volume”. The isolation volume is a value that is used in the set up of the
Integrated Canister System in PaintTool. Specific isolation volumes are found in section 9.2.6.1.
-385-
Figure 9-30 EO-6102-800-004 Sheet 1 of 5, P-500iA R30iA WB PAINTER ASM
WARNING
CLPMMCS30W40
19.1 POWER AND BRAKE
A components. Otherwise you could
REF
CLPMM000000059O EO-6102-100-011 WARNING

6.0 IS GROUND REF Always disconnect power to the robot
6.0 CARRIAGE GROUND before you perform any service or
8.0 BEARING AIR maintenance procedures. Otherwise,
REF
equipment.
CLPMM000000059O
9.5 ETHERNET UNLESS OTHERWISE NOTED:
REF SEE EG-00008 FOR LOCTITE REQUIREMENTS
CLPMMCS20W40
2X 12.0 PROCESS AIR
REF
CLPMMCS20W40
2X 12.0 PROCESS AIR
REF
CLPMMCS30W40 EO-6102-100-000
14.1 CASCADE
SEE EO-6102-100-011
REF
CLPMMCS30W40
17 ENCODER EO-6102-150-000
REF TAG ASSEMBLY
EO-6102-110-000X ITEM "A"

REF SEE TABLE
VIEW A
SCALE 1:4
EO6102-025-000X - ITEM "B"
SEE TABLE
NOTES:
FANUC ASSEMBLY NO. DESCRIPTION ITEM A ITEM B
EO6102-800-004A P-500iA-S-WB SIDE MACHINE, 1400MM OUTER ARM EO-6102-060-000 EO6102-025-000A 1. ADJUST AXIS 1 MOTOR PLATE POSITION TO ALLOW FOR 0.004" ± 0.001" BACKLASH
AT THE HIGH POINT OF MESH WITH THE RACK.
EO6102-800-004B P-500iA-T-WB TOP MACHINE, 1400MM OUTER ARM EO-6102-065-000 EO6102-025-000A 2. SEE ET-6102-800-006 FOR INITIAL GREASE REQUIREMENTS.
EO6102-800-004C P-500iA-SL-WB SIDE MACHINE, 1550MM OUTER ARM EO-6102-060-000 EO6102-025-000B 3. SEE TAG ASSEMBLIES FOR TAG AND HOLE LOCATIONS (EO-6102-150-000)
EO6102-800-004D P-500iA-TL-WB TOP MACHINE, 1550MM OUTER ARM EO-6102-065-000 EO6102-025-000B 4. UNLESS OTHERWISE SPECIFIED, USE PRIMER N AND LOCTITE PER EG-00008.
UNLESS OTHERWISE SPECIFIED, TORQUE ALL FASTENERS PER EG-00010.
5. FOR ROBOT BYPASS POSITION SEE SHEET 4. Standard Hardware Descriptions
6. FOR PROCESS LINE LENGTHS AND IDENTIFICATION TAGS SEE SHEET 5. FANUC Part No. Description
7. CONNECT EE-4560-655-001 FROM OUTER ARM FIBER OPTIC BULKHEAD TO SSHCM004070020C M4 X 0.7 X 20mm LG. Steel Socket Head Cap
KEYENCE UNIT IN PCE. SSHCM006100055G M6 X 1.0 X 55mm LG. Glass Filled Nylon Socket Head Cap
WSHFM016030040O M16 Flat Washer
WSHFM120240025O M12 Flat Washer
[EO-6102-800-004] REV *1
P-500iA R30iA WB PAINTER ASM SHEET 1 OF 5
-386-
WARNING
WARNING
equipment.
EO-4696-060-004 REF
9X SSHCM016200040C
9X WSHFM016030040O UNLESS OTHERWISE NOTED:
TO FASTEN INNER ARM (EO-4696-060-001A - SHOWN) EO-4696-060-006 REF SEE EG-00008 FOR LOCTITE REQUIREMENTS
TO AXIS 2 REDUCER (EO-9999-300-010) SEE EG-00010 FOR TORQUE SPECIFICATIONS
USE LOCTITE 262 (HDWMO000002450O)
TORQUE TO 319.0 15.5 N-m
SEE NOTE 4
EO9999-200-005K
EO-4696-060-003 REF
EO-4696-060-005 REF
9X SSHCM012175030C
9X WSHFM120240025O
TO FASTEN INNER ARM (EO-4696-060-001A - SHOWN)
TO AXIS 3 REDUCER (EO-9999-300-005)
USE LOCTITE 262 (HDWMO000002450O)
EO-4696-100-003 REF TORQUE TO 128.5 6.00 N-m
SEE NOTE 4
EO4696-100-002A REF
EO9999-200-005K
EO-4696-020-021 REF
EO6102-110-000X
EO4696-020-003A REF
[EO-6102-800-004] REV *1
-387-
WARNING
ENSURE DYNAMIC LOOP procedures when you install or remove
DOES NOT CONTACT components. Otherwise you could
CENTER TUBE IN THIS injure personnel or damge equipment
LOCATION.
GSKTEPDM3X3618X GSKTEPDM3X3618X WARNING

CUT AS REQUIRED TO WRAP BUNDLE CUT AS REQUIRED TO WRAP BUNDLE Always disconnect power to the robot
REMOVE PLUGS 2X TYRPPLT2SXXXXXX 2X TYRPPLT2SXXXXXX before you perform any service or
FROM MOTORS maintenance procedures. Otherwise,
ENSURE DYNAMIC LOOP equipment.
C DOES NOT CONTACT
CENTER TUBE IN THIS
LOCATION. UNLESS OTHERWISE NOTED:
B SEE EG-00010 FOR TORQUE SPECIFICATIONS
EE-4560-655-001 SEE NOTE 2

SEE NOTE 7
1X TYRPPLT2SXXXXXX
GSKTEPDM3X3618X PURGE AIR SUPPLY

PURGE AIR SUPPLY TO CARRIAGE
TO FRP CUT AS REQUIRED TO WRAP BUNDLE
2X TYRPPLT2SXXXXXX
REG
pTRIG (OPTIONAL) pIW
GROUND
SA2
POWER AXIS 3-6 SA1
SEAL BEAR
pSOL SAS
pAIR pBW
BRAKE
pCC
PURGE AIR SUPPLY PURGE ENCODER AXIS 3-6

TO PCE CASCADE
pDUMP2
PRESSURE TRANSDUCER
CABLE TURB1
pFLUSH FIBER OPTIC SPEED PICKUP
GSKTEPDM3X3618X pDUMP pPE
CUT AS REQUIRED TO WRAP BUNDLE
2X TYRPPLT2SXXXXXX TURB2
VIEW C DYNAMIC LOOP BUNDLE - ENSURE ELECTRICAL CABLES

VIEW B ARE IN THE CENTER WITH NYLON AIR LINES AROUND THE
SCALE 1:8 SCALE 1:12 OUTSIDE.
[EO-6102-800-004] REV *1
-388-
WARNING
WARNING
equipment.

EO-6102-535-000
81° BYPASS
D
EE-5156-312-001
E REF
47° REF
CAM SPLIT LINE WHEN D
ROBOT IS POSITIONED AS SHOWN
ROBOT BYPASS POSITION

EO6102-800-001A SHOWN
EO-5133-282-013
REF
2X SSHCM004070020C
SECTION D-D REF
SCALE 1 : 8 TORQUE TO 50[N*cm] (4.4lbf*in)
5 CAM
SETUP DIM
SECTION E-E
SCALE 1 : 8
[EO-6102-800-004] REV *1
-389-
WARNING
TUBEM080000026O
PAINT SUPPLY FROM
COLOR VALVES WARNING
ISOLATION LINE Always disconnect power to the robot
610 MM [24"] before you perform any service or
TUBEE062000064O OUTER SHEATH maintenance procedures. Otherwise,
PAINT OUT LINE equipment.
SEE NOTE 4
4X SSHCM006100055G
NEVER SHORTEN UNLESS OTHERWISE NOTED:
ISOLATION LINE. SEE EG-00008 FOR LOCTITE REQUIREMENTS
DUMP LINE PILOT (pDUMP2)

TUBMM004000000N
DUMP LINE PILOT (pDUMP)

TUBMM004000000N 2X TYRPPLT2SXXXXXX
TY-RAP PROCESS AND WTAGPDL1XXXXXXX (2)
APPLICATOR LINES SEE NOTE 1
CANISTER INLET PILOT (pCAN) NOTE: KEEP HIGH VOLTAGE CABLE
TUBMM004000000N AND FIBER OPTIC CABLE SEPARATE
FROM THE PROCESS BUNDLE
NOTES: Description Symbol APPROXIMATE LINE LENGTH IN MM

1. Solvair Solvent Pilot pSOL 380
1. PLACE IDENTIFICATION TAGS (WTAGPDL1XXXXXXX) AT BOTH ENDS OF EACH PROCESS LINE PER THE LINE LENGTH CHART.
2. Solvair Air Pilot pAIR 350
2. TORQUE ALL FASTENERS PER EG-00010. DO NOT USE LOCTITE ON PLASTIC FASTENERS. 3. Solvair CC Outlet Pilot pCC 390
4. SolvAir 2T Pilot pWASH 390
3. PROCESS LINE LENGTHS ARE COLOR DEPENDANT BASED ON LINE LENGTH CHART.
5. SolvAir pSOL2/pDUMP3 pSOL2/pDUMP3 390
4. PAINT SUPPLY LINE (ISOLATION LINE) MUST BE 610 MM (24") LONG. DO NOT SHORTEN. ALWAYS REPLACE 6. pCAN, Canister Inlet pCAN 870
WITH TUBEM080000026O (8 MM OD x 6 MM ID FEP), DO NOT SUBSITUTE WITH ANY OTHER PRODUCT! 7. Dump valve 1 pDUMP 940
8. Dump valve 2 pDUMP2 920
5. SOLVAIR VALVE ALWAYS STAYS IN POSITION SHOWN FOR ALL COLOR COMBINATIONS.
9. Paint Supply Isolation Line PS 610
6. ADD SSSM00600010N (QTY 10) TO ANY UNUSED M6 TAPPED HOLES IN OUTER ARM FOR COLOR VALVE
COMBINATIONS. USE HDWMO000003658O (PRIMER N) AND HDWMO000003367O (LOCTITE 222)
[EO-6102-800-004] REV *1
-390-
Figure 9-35 EO-5093-895-002 Sheet 1 of 8, P-700 WB PROCESS HARDWARE ASM
WARNING
PULL COLOR LINES UP THRU CENTER TUBE AFTER * SEE extreme care and follow proper lifting
COLOR LINE ASSEMBLY IS ATTACHED TO ROBOT TABLE procedures when you install or remove
NOTES: SEE CABLE CARRIER ASSEMBLY (EO-5093-4XX-000) components. Otherwise you could
FOR ADDITIONAL COLOR LINE ROUTING injure personnel or damge equipment
SEE SHEET 8 ENSURE THAT END CAPS REMAIN ON HOSE BUNDLES
WARNING
equipment.
CONNECT AIR FROM HEAT EXCHANGER UNLESS OTHERWISE NOTED:

(EO-5093-275-000) TO AIR MANIFOLD. SEE EG-00008 FOR LOCTITE REQUIREMENTS
AIR SUPPLY MANIFOLD ASM

EO-5093-170-025
REF.
SEE NOTE 9
'COLOR STACK ASM'
SEE TABLE ON SHEET 8
SEE NOTE 7 EO-5093-275-000
VIEW A
SEE SHEET 5
LONGEST HOSE LOOP

FROM CLAMP TO J1 RING
TO BE 1050MM
'SHOULDER COVER'
(NOT SHOWN)
VIEW B
SEE SHEET 6 'COLOR LINE ASM'
VIEW C
SEE SHEET 2
EO-5093-070-002 (NOT SHOWN)

P-700iA 2K OUTERARM HOSE COVER
ATTACH OVER HOSE CLAMPS
PROCESS CONTROL MANIFOLD ASM
EO-5093-533-000
EO5093-895-002A-M
REF.
PEDESTAL CONFIG. FANUC Part No.
Description
SHOWN SSHCM006100020G M6 X 1.0 X 20mm LG. Glass Filled Nylon Socket Head Cap
[EO-5093-895-002] REV *49

P-700 WB PROCESS HARDWARE ASM SHEET 1 OF 8
-391-
* SEE WARNING
TABLE Some components are heavy. Use
WARNING
equipment.

SEE NOTE 9
pCAN pDUMP2
EO-HOSE-011-004 EO-HOSE-011-004
L=810mm L=810mm
pDUMP
EO-HOSE-011-004 pPAINT
L=810mm EO-HOSE-011-004
L=810mm
J2=5.0°
SEE NOTE 7
ATTACH USING (4) STAINLESS STEEL SCREWS EO5093-895-002A-M

INCLUDED WITH COLOR LINE ASSEMBLY
EO-5093-515-006
CONNCT AIR SUPPLY LINE (BLUE)
SEE NOTE 2 PEDESTAL CONFIG.
ATTACH USING (2) STAINLESS STEEL SCREWS
TO AIR FITTING ON SOLVAIR BLOCK SHOWN
SEE NOTE 2
CONNCT SOLVENT SUPPLY LINE
CONNECT COLOR SUPPLY & RETURN TO SOL FITTING ON SOLVAIR BLOCK
FIBER OPTIC CONNECTOR & COVER LINES TO COLOR STACK ASSEMBLY
EO-5093-540-007 SEE NOTE 5
REF.
CONNECT DUMP LINES
TO DUMP FITTINGS
2X SSHCM006100020G
CONNECT WASH LINE (6x4 TUBE)
TO WASH FITTING
EO-5093-310-014
EO5093-262-004C
CONNECT PAINT LINE

(6x3 w/ MACHINED END) pDI & pDAIR
TO PAINT IN FITTING 2X EO-HOSE-011-004
L=500mm
ATTACH USING (4) STAINLESS STEEL SCREWS CONNCT WASH LINE TO

INCLUDED WITH COLOR LINE ASSEMBLY 2T FITTING ON SOLVAIR BLOCK ATTACH USING (4) STAINLESS STEEL SCREWS
SEE NOTE 2 VIEW C
FROM SHEET 1 INCLUDED WITH COLOR LINE ASSEMBLY
SCALE 1:10 SEE NOTE 2
[EO-5093-895-002] REV *49

-392-
WARNING
* SEE Some components are heavy. Use
TABLE extreme care and follow proper lifting
PULL COLOR LINES UP THRU CENTER TUBE AFTER WARNING

COLOR LINE ASSEMBLY IS ATTACHED TO ROBOT Always disconnect power to the robot
SEE CABLE CARRIER ASSEMBLY (EO-5093-4XX-000) before you perform any service or
FOR ADDITIONAL COLOR LINE ROUTING maintenance procedures. Otherwise,
ENSURE THAT END CAPS REMAIN ON HOSE BUNDLES you could injure personnel or damage
equipment.
CONNECT AIR FROM HEAT EXCHANGER UNLESS OTHERWISE NOTED:

(EO-5093-275-000) TO AIR MANIFOLD SEE EG-00008 FOR LOCTITE REQUIREMENTS
AIR SUPPLY MANIFOLD ASM.

(EO-5093-170-025)
SEE NOTE 9
'COLOR STACK ASM'

SEE TABLE ON SHEET 8 EO-5093-275-000
SEE NOTE 7
VIEW A
SEE SHEET 5
'SHOLDER COVER'
'COLOR LINE ASM' (NOT SHOWN)
VIEW B SEE TABLE ON SHEET 8
SEE SHEET 6
VIEW D
SEE SHEET 4
EO-5093-070-002
(NOT SHOWN)
P-700iA 2K OUTERARM HOSE COVER
ATTACH OVER HOSE CLAMPS
EO5093-895-002N-Z
RAIL CONFIGURATION
PROCESS CONTROL MANIFOLD ASM
(EO-5093-533-000) SHOWN
[EO-5093-895-002] REV *49
-393-
WARNING
WARNING
equipment.

pDUMP2 EO-5093-310-017
EO-HOSE-011-004 ATTACH USING (2) NYLON SCREWS
L=810mm pPAINT SEE NOTE 9
INCLUDED WITH 3 WAY MANIFOLD
EO-HOSE-011-004
pCAN L=810mm
EO-HOSE-011-004
L=810mm CONNECT DUMP LINES TO
DUMP FITTINGS
pDUMP
EO-HOSE-011-004
L=810mm
J2=5.0°
SEE NOTE 7
CONNECT AIR LINE (BLUE)

EO5093-895-002N-Z
EO-5093-515-010
CONNECT TO DUMP
TO FITTING ON TOP ON INSOLATION BLOCK RAIL CONFIGURATION
EO5093-262-007A
CONNECT TO PAINT IN SHOWN
CONNECT AIR SUPPLY LINE (BLUE) SEE NOTE 2
ATTACH USING (2) STAINLESS STEEL SCREWS TO TEE FITTING AS SHOWN
INCLUDED WITH COLOR LINE ASSEMBLY ON COLOR STACK ASSEMBLY
SEE NOTE 2
CONNECT COLOR SUPPLY & RETURN CONNECT SOLVET SUPPLY LINE
LINES TO COLOR STACK ASSEMBLY TO SOL FITTING ON SOLVAIR BLOCK
FIBER OPTIC CONNECTOR & COVER SEE NOTE 5
(EO-5093-540-007)
CONNECT LONG ISOLATION LINE

(EO5093-262-007B) TO ISOLATION BLOCK ASM.
pPI
EO-5093-310-013 EO-HOSE-011-004
ATTACH USING (3) NYLON SCREWS L=480
INCLUDED WITH pIAIR
ISOLATION MANIFOLD ASM. EO-HOSE-011-004
L=510
SEE NOTE 2 ATTACH USING (4) STAINLESS STEEL SCREWS
CONNECT WASH LINE TO VIEW D INCLUDED WITH COLOR LINE ASSEMBLY
2T FITTING ON SOLVAIR BLOCK FROM SHEET 3 SEE NOTE 2
SCALE 1:10
[EO-5093-895-002] REV *49

-394-
WARNING
BEAR * SEE extreme care and follow proper lifting
FROM ITEM 'B' pSOL, p2T, pAIR, & pCC TABLE procedures when you install or remove
SEE NOTE 3 components. Otherwise you could
SA1 & SA2 injure personnel or damge equipment
FROM ITEM 'B'
D/Q1 & D/Q2 WARNING
FROM ITEM 'A' Always disconnect power to the robot
CPX before you perform any service or
FROM ITEM 'A' maintenance procedures. Otherwise,
BEAR pC13-pC24 you could injure personnel or damage
FROM ITEM 'A' SEE NOTE 3 pC1-pC12 equipment.
SEE NOTE 3
SAS SEE NOTE 3
FROM ITEM 'B' UNLESS OTHERWISE NOTED:
SPEED SEAL
FROM ITEM 'C' FROM ITEM 'B'
TBSP1 & TBSP2 ATTACH USING (5) STEEL SCREWS

FROM ITEM 'A' PROVIDED WITH INNER ARM PROCESS ASM.
SEE NOTE 2
TURB1 & TURB2

CONNECT EXHAUST LINE TO FROM ITEM 'B'
CHECK VALVE COMMUNICATION CABLE
pSOL, pAIR, & pCC ROUTED EE-5405-163-003
BEHIND PCE PLATE FROM CARRIAGE
REF. POWER CABLE
EE-5093-406-001
'PCE ASM' FROM CARRIAGE
SEE TABLE ON SHEET 8 VIEW A REF.
FROM SHEET 1
SCALE 1:5
ITEM 'A'
AIR SUPPLY MANIFOLD ITEM 'B'
EO-5093-170-025 REF. PROCESS CONTROL MANIFOLD
EO-5093-533-000 REF.
ITEM 'C'
FIBER OPTIC CONNECTOR
EO-5093-540-007 REF.
[EO-5093-895-002] REV *49

-395-
WARNING
* SEE extreme care and follow proper lifting
TABLE procedures when you install or remove
PROVIDED WITH COLOR STACK ASSEMBLY WARNING
TORQUE TO 2.0 N-m (0.74 ft-lbs) Always disconnect power to the robot
NO LOCTITE ON THESE SCREWS before you perform any service or
equipment.

ROUTE SOL2 ATTACH COLOR CHANGER PILOT LINES

BETWEEN PILOT LINES AS SHOWN
SEE NOTE 4
VIEW B
FROM SHEET 1
[EO-5093-895-002] REV *49

-396-
WARNING
WARNING
equipment.

EO-4696-330-000 REF
2X SSHCM006100016G REF
EO-4696-330-022 REF
EO-5093-310-000 REF
[EO-5093-895-002] REV *49

-397-
WARNING
QTY See injure personnel or damge equipment
Part Number Description Color Lines Asm PCE Asm Color Stack Asm Shoulder Cover "A" Sheets
EO5093-895-002A 4 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000A EO5093-115-000A EO5093-510-002A EO-5093-070-003 0 1,2,5-8
EO5093-895-002B 8 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000B EO5093-115-000B EO5093-510-002B EO-5093-070-003 0 1,2,5-8
WARNING
EO5093-895-002C 12 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000C EO5093-115-000C EO5093-510-002C EO-5093-070-003 0 1,2,5-8 before you perform any service or
EO5093-895-002D 16 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000D EO5093-115-000D EO5093-510-002D EO-5093-070-004 0 1,2,5-8 maintenance procedures. Otherwise,
EO5093-895-002E 20 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000E EO5093-115-000E EO5093-510-002E EO-5093-070-004 0 1,2,5-8 equipment.
EO5093-895-002F 24 Color (Bell) Recirc. (20 m) Waterborne EO5093-262-000F EO5093-115-000F EO5093-510-002F EO-5093-070-004 0 1,2,5-8
EO5093-895-002G 4 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000A EO5093-115-000A EO5093-510-002A EO-5093-070-003 4 1,2,5-8 UNLESS OTHERWISE NOTED:
EO5093-895-002H 8 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000B EO5093-115-000B EO5093-510-002B EO-5093-070-003 8 1,2,5-8 SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO5093-895-002J 12 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000C EO5093-115-000C EO5093-510-002C EO-5093-070-003 12 1,2,5-8
EO5093-895-002K 16 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000D EO5093-115-000D EO5093-510-002D EO-5093-070-004 16 1,2,5-8
EO5093-895-002L 20 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000E EO5093-115-000E EO5093-510-002E EO-5093-070-004 20 1,2,5-8
EO5093-895-002M 24 Color (Bell) Non-recirc. (20 m) Waterborne EO5093-262-000F EO5093-115-000F EO5093-510-002F EO-5093-070-004 24 1,2,5-8
EO5093-895-002N 4 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000G EO5093-115-000A EO5093-510-002A EO-5093-070-003 0 3-8
EO5093-895-002P 8 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000H EO5093-115-000B EO5093-510-002B EO-5093-070-003 0 3-8
EO5093-895-002Q 12 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000J EO5093-115-000C EO5093-510-002C EO-5093-070-003 0 3-8
EO5093-895-002R 16 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000K EO5093-115-000D EO5093-510-002D EO-5093-070-004 0 3-8
EO5093-895-002S 20 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000L EO5093-115-000E EO5093-510-002E EO-5093-070-004 0 3-8
EO5093-895-002T 24 Color (Bell) Recirc. (20 m) Waterborne Rail Config. EO5093-262-000M EO5093-115-000F EO5093-510-002F EO-5093-070-004 0 3-8
EO5093-895-002U 4 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000G EO5093-115-000A EO5093-510-002A EO-5093-070-003 4 3-8
EO5093-895-002V 8 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000H EO5093-115-000B EO5093-510-002B EO-5093-070-003 8 3-8
EO5093-895-002W 12 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000J EO5093-115-000C EO5093-510-002C EO-5093-070-003 12 3-8
EO5093-895-002X 16 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000K EO5093-115-000D EO5093-510-002D EO-5093-070-004 16 3-8
EO5093-895-002Y 20 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000L EO5093-115-000E EO5093-510-002E EO-5093-070-004 20 3-8
EO5093-895-002Z 24 Color (Bell) Non-recirc. (20 m) Waterborne Rail Config. EO5093-262-000M EO5093-115-000F EO5093-510-002F EO-5093-070-004 24 3-8
NOTES:
1. 24 COLOR RECIRCULATING WB SHOWN
2. PRIME ALL STEEL & STAINLESS STEEL FASTENERS WITH PRIMER N AND USE LOCTITE PER
EG-00008 UNLESS OTHERWISE NOTED. DO NOT USE ANY LOCTITE ON PLASTIC
FASTENERS. UNLESS OTHERWISE NOTED, TIGHTEN ALL FASTENERS ACCORDING TO EG-
00010.
FITMO000002138O 3. SEE INNER ARM PROCESS ASSEMBLY (EO5093-115-000X) FOR ADDITIONAL INFORMATION &
REF EG-00390 FOR SCHEMATIC
HOSCO #RY-6-312 4. SEE COLOR STACK ASSEMBLY (EO5093-510-002X) FOR ADDITIONAL INFORMATION
5. USE COLOR LINE INSTALLATION TOOLS (TOOLO000000048O & TOOLO000000050O) TO
INSTALL COLOR LINES INTO COLOR STACK ASSEMBLY
6. <OPEN>
7. JOG ROBOT TO POSITION SHOWN ON SHEET 4 PRIOR TO INSTALLING COLOR LINE ASM.
FITMO000002139O 8. EO-5093-895-020 TO BE PACKAGED AND SHIPPED WITH ASSEMBLY.
REF 9. BEFORE INSTALLING 'SHOULDER COVER', REMOVE THE UPPER HOSE BUNDLE RETAINING
HOSCO #9X12-38 SG STICK AND RETURN IT TO STOCK.
FITMO000002137O
REF
HOSCO #6X8-38 SG
EO-5093-895-020
QTY "A"
SEE TABLE ABOVE
SEE NOTE 8 -
SHEET 8
[EO-5093-895-002] REV *49

-398-
Figure 9-43 EO-6263-895-002 Sheet 1 of 5, WB PROCESS INSTALLATION
W A R N IN G
S o m e co m p o n e nts a re h e avy. U se
extre m e ca re a n d fo llo w pro p er liftin g
proce d ure s w h e n yo u in sta ll or rem ove
co m p o n e nts. O th erw ise yo u co u ld
in ju re p erso n n e l o r d am a g e e q u ipm e nt
W A R N IN G
A lw a ys d isco n n ect p ow er to th e ro b ot
b efo re yo u p erform a ny se rvice o r
C O LO R LIN E S A SM . V IE W "A " & "B " m a inte n a nce p ro ce d ures. O th erw ise ,
E O 6 2 6 3-2 6 2-0 0 0A TH R U -0 0 0C M ~ R EF. O U TER AR M C O N N EC TIO N S & O U TER AR M C O V ER S yo u co u ld in ju re p erso n n e l or d am a g e
(S E E SH E ET S 2 & 3) e q u ipm e nt.
U N LE S S O TH ER W IS E N O TED :
S E E EG -0 0 0 0 8 FO R LO C TIT E R EQ U IR EM EN TS
S E E EG -0 0 0 1 0 FO R TO R Q U E S P EC IF IC ATIO N S
V IE W "C "
C A SC AD E A SM . C O LO R C H AN G ER C O N N EC TIO N S
E O -6 2 6 3-5 4 1-0 0 0 ~ R E F. (S E E SH E ET 4)
V IE W "D "
PC E C O N N EC TIO N S
(S E E SH E ET 5)
E O -6 2 6 3-2 8 0-0 00
(S E E H E A T E X C H A N G E R A S M
D R A W IN G F O R D E T A IL S O F
H O S E C O N N E C T IO N S )
TU R RET AIR SU P PLY PLATE
E O 6 2 6 3-5 3 3-1 0 0A TH R U -1 0 0F ~ R E F.
C O N N E C T P ILO T LIN E S T O
T U R R E T A IR S U P P L Y P LA T E
NO TE:
1. R O B O T S H O W N IN R IA O C O N F IG U R A T IO N , 2 4 C O L O R S
2. P R IM E , L O C T IT E , & T O R Q U E A L L F A S T E N E R S A C C O R D IN G T O E G 0 0 0 0 8 & E G 0 0 0 10
3. S E E S IN G L E S .A . P C E A S M D R A W IN G (E O 6 2 6 3-1 1 6-0 0 0X ) & E G 0 0 5 4 7 F O R A D D IT IO N A L IN F O R M A T IO N & S C H E M A T IC S
4. S E E D U A L S .A . P C E A S M D R A W IN G (EO 6 2 6 3-1 2 6-0 0 0X ) & E G 0 0 5 4 8 F O R A D D IT IO N A L IN F O R M A T IO N & S C H E M A T IC S
5. S E E C O L O R L IN E A S M D R A W IN G S (EO 6 2 6 3-2 6 2-0 0 0X X ) F O R A D D IT IO N A L IN F O R M A T IO N
6. S E E C O L O R C H A N G E R A S M D R A W IN G (EO 6 2 6 3-5 1 0-0 0 2X ) F O R A D D IT IO N A L IN F O R M A T IO N
7. S E E C A S C A D E A S M D R A W IN G (EO -6 2 6 3-5 4 1-0 0 0) F O R A D D IT IO N A L IN F O R M A T IO N S tanda rd H ardw a re D escrip tion s
F A N U C P art N o . D e s c r i p t io n
M 6 X 1.0 X 25 m m LG . S tain le ss S tee l H e x H ead M a ch in e
S H H M M 006100025 S
S crew
[EO -6 2 6 3-8 9 5-0 0 2] REV B

W B PR O C E S S IN STAL LAT IO N SHEET 1 O F 5
-399-
W A R N IN G
S om e com p on e nts are h e avy. U se
extrem e care an d follo w pro p er liftin g
proce d ures w he n yo u in sta ll or rem ove
com p on e nts. O th erw ise you co u ld
P R O C E S S C O N T R O L M A N IF O LD in jure p erso n n el or d am a g e e q uipm e nt
E O -50 9 3-5 3 3-00 0 ~ R E F . E O -62 6 3-3 1 0-0 01
(A T T A C H U S IN G S C R E W S P R O V ID E D
W IT H D U M P M A N IF O LD A S M .)
V IE W "A " W A R N IN G
(O U T E R A R M C O N N E C T IO N S ) A lw ays d iscon n ect p ow er to the rob ot
(FR O M S H E ET 1) b efore you perform any service or
m a inte n ance proce d ures. O th erw ise,
E O 50 9 3-2 6 2-00 7C ~ R E F . you co u ld in ju re p erso nn e l or dam a ge
C O N N E C T T O IS O LA T IO N M A N IF O LD A S M . e q uipm e nt.
E O -50 9 3-3 1 0-012 S E E EG -0 00 0 8 F O R LO C T ITE R EQ U IR E M EN T S
(A T T A C H U S IN G S C R E W S P R O V ID E D S E E EG -0 00 1 0 F O R TO R Q U E S P EC IFIC A TIO N S
W IT H IS O LA T IO N M A N IF O LD A S M .)
pP I
E O -H O S E -0 1 1-0 04
L E N G T H = 48 0-m m
pPIAIR
EO -H O S E-01 1-0 04
LEN G TH = 51 0-m m
EO 5 0 93-2 62-0 0 7A
C O N NEC T B ET W E EN IS O LAT IO N M AN IF O LD A SM &
"P AIN T IN " PO R T O N C AN IS TER A SM .
P LG M M 0 0 0 00 0 0 06P
(S E E N O T E 1 T H IS S H E E T ) E O -H O S E -01 1-0 04
pP A IN T : LE N G T H = 8 10-m m
pC A N : LE N G T H = 8 10-m m
pD U M P : LE N G T H = 8 1 0-m m
IN S T A L L F IB E R C A B LE pD U M P 2: LE N G T H = 8 10-m m
C O N N E C T IS O -C O R E D U M P LIN E S
T O D U M P M A N IF O LD A S M .
C O N N E C T B LU E A IR LIN E F R O M J3 C LA M P
T O F IT T IN G O N IS O LA T IO N M A N IF O LD A S M
AS SHO W N
E O -5 09 3-5 1 5-0 11
C O N N E C T B E T W E E N D U M P M A N IF O LD A S M &
"D U M P " P O R T O N C A N IS T E R A S M .
R O U TE H IG H -VO LTAG E C A BLE A S SH O W N

R O U T E ST ATIO N AR Y LIN ES
TH R U T H IS O P EN IN G
R O U TE D YN A M IC LIN E S O U T
T O A R M T H R U T H IS O P EN IN G R O U T E "W A SH " LIN E A S S H O W N
C A N IS T E R M A N IF O LD C O N N E C T IO N S
NO TE:
1. S H A P E A IR S E N S E IS N O T N E E D E D . R E M O V E P R O C E S S C O N T R O L M A N IF O LD (EO -5 09 3-53 3-0 0 0)
& U N P LU G S H A P E A IR S E N S E LIN E O N T H E B A C K . P LU G S H A P E A IR S E N S E F IT T IN G O N T H E
M A N IF O LD U S IN G P LG M M 0 0 00 0 0 0 06P (SO T H A T F IT TIN G IS P LU G G E D F R O M IN S ID E F R P ).
[EO -6 26 3-89 5-0 02] REV B

W B PR O C E S S IN S TA LLA TIO N SHEET 2 O F 5
-400-
W A R N IN G
S om e com po n e nts are h eavy. U se
extrem e care a n d fo llo w prop er liftin g
proce d ures w h e n you in stall o r rem ove
V IE W "B "
com p o ne nts. O th erw ise yo u co u ld
in ju re p erso n n el or dam a ge e qu ipm e nt
(O U T E R A R M C O V E R S ) W A R N IN G
(F R O M S H E ET 1) A lw ays d isco n n ect p ow er to th e ro b ot
b efore yo u p erform any service or
m a inte n a nce proce d ures. O th erw ise,
yo u co u ld in ju re p erson n e l or dam ag e
e q u ipm e nt.
U NLE S S O T H ER W IS E N O T ED :
S E E E G -0 0 0 1 0 F O R T O R Q U E S P EC IF IC AT IO N S
E O 5 0 93-0 20-0 0 4A
E O -5 0 9 3-0 2 0-0 05
1 6X S H H M M 0 0 6 1 0 0 0 25S
E O -6 2 4 6-0 2 0-0 16
6X E O -5 0 9 3-0 2 0-0 17
[E O -6 2 6 3-8 95-0 0 2] REV B

W B PR O C E S S IN S T AL LAT IO N SH EET 3 O F 5
-401-
W A R N IN G
S o m e com p o n e nts a re h e avy. U se
extre m e care a n d fo llo w p ro p er liftin g
pro ce d ure s w h e n yo u in sta ll o r rem o ve
FACE "X" V IE W "C " co m p o n e nts. O th erw ise yo u co u ld

(S E E N O TE 3)
(C O L O R C H A N G E R C O N N E C T IO N S ) W A R N IN G
(FR O M SH E ET 1)
A lw a ys d isco n n ect p ow e r to th e ro b ot
b efo re yo u p erform a ny se rvice or
m a inte n a nce pro ce d ures. O th erw ise,
C O N NEC T "AIR " SU P PLY F R O M J2 C LAM P TO T EE yo u co u ld in ju re p erso n n e l o r d am a g e
J2 C LAM P T R IM M IN G TU B E FR O M FAC E "X" A S IN DIC ATE D : e q u ipm e nt.
C O LO R BU N DLE E XIT 2 4-C LR = 4 7 5-m m
(S E E N O TE 1) 2 0-C LR = 4 5 0-m m
1 6-C LR = 4 2 5-m m
S E E E G -0 0 0 0 8 FO R LO C T ITE R EQ U IR EM EN TS
1 2-C LR = 4 0 0-m m
8-C LR = 3 7 5-m m
4-C LR = 3 5 0-m m C O N NE C T "AIR " SU P PLY FR O M J3 C LAM P TO TEE
TR IM M IN G T U B E 8 0-m m FR O M F AC E "Y"
J2 C LA M P P IL O T B U N D LE E X IT
(S E E N O T E 1)
FACE "Y"
(S E E N O T E 3)
C A P O F F U N U S E D P IL O T T U B E S
O N P ILO T B U N D L E U S IN G
C A P M O 0 0 0 0 0 0 0 9 8O , T H E N
C O IL U P & S E C U R E T O H O LE S
S H O W N U S IN G T IE -R A P S
C O N N E C T LV C A B L E F R O M J2 C LA M P
C O N N E C T H V C A B LE
F R O M J3 C L A M P
C O N NE C T "SO L 2" F R O M J2 C LAM P C O N N E C T L O N G IS O LA T IO N L IN E

TR IM M IN G T U B E FR O M F AC E "X" (EO 5 0 9 3-2 6 2-0 0 7B ~ R E F .) F R O M J3 C L A M P
A S IN DIC AT ED :
2 4-C LR = 7 0 0-m m 1 2-C LR = 6 2 5-m m
2 0-C LR = 6 7 5-m m 8-C LR = 6 0 0-m m
1 6-C LR = 6 5 0-m m 4-C LR = 5 7 5-m m
C O N N E C T P ILO T LIN E S
EO -6 2 6 3-5 4 1-0 0 0 ~ R EF. F R O M J2 C L A M P
(AT TAC H U SIN G SC REW S PR O V ID ED p V A C & pV A IR
W IT H C A SC AD E A SM ) (S E E N O T E 1)
C O N NE C T "SO L" F R O M J2 C LA M P, TR IM M IN G
TU B E FR O M FAC E "X" A S IN DIC ATE D :
2 4-C LR = 7 0 0-m m 1 2-C LR = 6 2 5-m m
2 0-C LR = 6 7 5-m m 8-C LR = 6 0 0-m m
1 6-C LR = 6 5 0-m m 4-C LR = 5 7 5-m m
C O N NE C T "W A SH " F R O M J3 C LAM P

TO "2T" O N SO LV AIR BLO C K, TR IM M IN G
TU B E FR O M FAC E "Y" A S IN DIC ATE D :
2 4-C LR = 6 3 0-m m
2 0-C LR = 5 8 0-m m E O 6 2 6 3-5 1 0-0 0 2X ~ R EF .
1 6-C LR = 5 3 0-m m (AT TAC H U SIN G S C RE W S
1 2-C LR = 4 8 0-m m P R O V ID E D W ITH C O LO R
8-C LR = 4 3 0-m m C HAN G ER A SM )
4-C LR = 3 8 0-m m
C O N N E C T C O LO R S U P P LY /R E T U R N
L IN E S F R O M J2 C L A M P S T O C O L O R
CHANG ER ASSEM BLY
(S E E N O T E 1 )
(S E E N O T E 2 )
C O N N EC T PILO T LIN ES
FR O M J2 C LAM P
pSO L, pSO L 2, pAIR , pC C, p 2T NO TE:
(S E E N O TE 1) 1. F O R C L A R IT Y , C O LO R LIN E S , C O L O R R E T U R N L IN E S , & P IL O T LIN E S
C O N N E C T P ILO T LIN E S C O M IN G O U T O F J2 C L A M P & IN T O C O L O R C H A N G E R A R E N O T S H O W N
F R O M J2 C LA M P 2. U S E C O LO R LIN E IN S T A L LA T IO N T O O L S (T O O L O 0 0 0 0 0 0 0 4 8O &
FOR ALL CO LO R S T O O L O 0 0 0 0 0 0 0 5 0O ) T O IN S T A L L C O L O R L IN E S IN T O C O L O R S T A C K A S M
(S E E N O T E 1) 3. T R IM LIN E S T O L E N G T H S IN D IC A T E D F R O M J2 & J3 C L A M P F A C E S
(F A C E "X " & F A C E "Y ") A S S H O W N
[EO -6 2 6 3-8 9 5-0 0 2] REV B

W B PR O C E S S IN STAL LATIO N SHEET 4 O F 5
-402-
W A R N IN G
S o m e com p o n e nts a re h e avy. U se
pro ce d ure s w h e n yo u in sta ll o r rem o ve
V IE W "D " W A R N IN G
(P C E C O N N E C T IO N S ) A lw a ys d isco n n ect p ow e r to th e ro b ot
b efo re yo u p erform a ny se rvice or
(F R O M S H E ET 1) m a inte n a nce pro ce d ures. O th erw ise,
yo u co u ld in ju re p erso n n e l o r d am a g e
e q u ipm e nt.
C O M M U N IC A T IO N S C A B L E
FRO M PEDESTAL ~ REF.
PO W ER C A BLE U NLE S S O TH ER W IS E N O TE D :
FR O M P ED E ST AL ~ R EF. S E E E G -0 0 0 0 8 FO R LO C T ITE R EQ U IR EM EN TS
A T T A C H A C C O R D IN G T O E G 0 0 0 0 8 & E G 0 0 0 10 CONNECT EXHAUST
U S IN G S C R E W S P R O V ID E D W IT H P C E A S M . LIN E T O C H E C K V A L V E S E E E G -0 0 0 1 0 FO R T O R Q U E S P EC IFIC ATIO N S
TU RB 1 & TU RB2 B E AR A IR
FR O M ITE M "A" FR O M ITEM "A"
TB S P1 & TB S P2 C O LO R PILO TS
FR O M ITEM "D " SH A P E AIR 2 F R O M IT EM "C "
FR O M ITEM "A" C O L O R P ILO T S
F R O M IT E M "C "
B E AR AIR PR O C E S S/SH A P E AIR SU P PLY
FR O M ITEM "D " FR O M ITEM "D " B EL L S P E ED
FR O M ITEM "B"
SH A P E A IR 1 P R O C E S S /S H A P E A IR S U P P LY P R O C E S S P ILO T S
FR O M ITEM "A" F R O M IT E M "D " F R O M IT E M S "A " & "C "
D R Y A IR
F R O M IT E M "A "
S E AL AIR
FR O M IT EM "A"
IT E M "A " IT E M "B " IT E M "C " IT E M "D "

P R O C E S S C O N TR O L M A N IFO LD (F R P) F IB ER O PTIC C O N NEC T O R (FR P) TU R RET AIR SU P PLY PLATE (TU R RET) P ED E STAL AIR SU P PLY (P ED E ST AL)
EO -5 0 9 3-5 3 3-0 0 0 ~ R EF. EO -5 0 9 3-5 4 0-0 0 7 ~ R EF . EO 6 2 6 3-5 3 3-1 0 0A TH R U -1 0 0F ~ R EF. EO -6 2 6 3-5 3 1-1 4 1 ~ R E F.
[EO -6 2 6 3-8 9 5-0 0 2] REV B

W B PR O C E S S IN STAL LATIO N SHEET 5 O F 5
-403-
Figure 9-48 EO-5093-262-007, ISOLATION LINE
WARNING
WARNING
equipment.

8X EO9999-200-001E
DIM "A"
TUBEM080000026O
EO-4696-310-037 EO-4696-310-038
FANUC PART NO. DESCRIPTION DIM "A"

EO5093-262-007A SHORT ISOLATION LINE 340mm
EO5093-262-007B LONG ISOLATION LINE 1600mm
NOTES:
1. TUBING MUST BE CUT SQUARE TO WORK PROPERLY WITH FITTINGS.
2. BARREL FITTING MUST BE REPLACED WHEN TUBING IS REPLACED.
3. MARK TUBE WITH "ISOLATION" USING WTAGPDL1XXXXXXX PLACE LABEL 50mm
FROM END OF TUBING.
[EO-5093-262-007] REV *1
ISOLATION LINE SHEET 1 OF 1
-404-
Figure 9-49 EO-5093-310-011, ISOLATION MANIFOLD ASSEMBLY
WARNING
WARNING
equipment.

2X EO-5513-003-000 SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-5093-310-009
2X EO9999-200-003I
2X EO-5093-310-003
2X SSHCM006100016S
FITCO000001365O
2X FITMO000001982O 2X EO-4696-310-036
2X EO9999-200-001N
4X EO9999-200-001E

[EO-5093-310-011] REV C1
ISOLATION MANIFOLD ASSEMBLY SHEET 1 OF 1
-405-
Figure 9-50 EO-5093-310-013, ISOLATION MANIFOLD ASSEMBLY
WARNING
WARNING
2X EO-5513-003-000 before you perform any service or
equipment.

EO9999-200-003I
EO-5093-310-012
SSHCM006100016S
EO-5093-310-003
2X EO9999-200-001N SEE NOTE 1
2X FITMO000001982O
3X SSHCM006100025G EO9999-200-003I
3X EO9999-200-005Q
2X SSHCM006100025G
SSHCM006100016S
EO-5093-310-003
FITEO000001688O
SEE NOTE 1
NOTES:
1. TAPE NOTED HOLES TO RESTRAIN O-RINGS Standard Hardware Descriptions
[EO-5093-310-013] REV C2
ISOLATION MANIFOLD ASSEMBLY SHEET 1 OF 1
Installation
The isolation line is installed differently in the P-500 than it is in the P-700 and P-250.
-406-
P-500 Installation:
On P-500, the isolation line, shown in Figure 9-17 EO-6102-800-004, consists of a 610 mm length of 6 x 8 mm FEP tubing (TUBEMO80000026O), a barrel fitting (EO-4696-310-029), two o-rings (EO9999-200-001E) and a square-cut
o-ring (EO9999-200-003I). Assemble this line by installing an o-ring into the gland inside the barrel and an o-ring into the gland on the outside of the narrow end of the barrel. Use hose tool EO-4526-700-008 to mark the engagement
depth on the tubing with a permanent marker, then grip the tubing with hose wrench EO-4526-701-000 and twist the barrel onto the end of the tubing until the end of the barrel is even with the line drawn on the tubing. The line is now
ready for installation.
Line Description P-500 WB

Paint Isolation Lines TUBEM080000026O &
TUBEE062000064O OUTER SHEATH
Paint Isolation Line Length 610 mm
Table 9-1: P-500 WB Paint Isolation Line Assemblies
Prepare to remove the isolation line by running a “Superpurge” cycle. Then remove the arm manifold (EO-4696-310-002) by removing 7 M6 plastic screws (SSHCM00610040G) from the valve side of the canister manifold and
loosening 4 hold down screws on the hose side.. Disconnect the 3 barrel fittings from the Canister Manifold.
Next, disconnect the isolation line from the Serto fitting on the color changer assembly (EO-6102-510-005). Pull on the barrel to slide the isolation line through the insulating tube and arm manifold to remove. Remove the square cut o-
ring in the bottom of the barrel socket.
Install a new isolation line assembly by passing the plain end of the FEP tubing through the arm manifold. Place the insulating tubing over the FEP tubing. Install a square cut o-ring into the barrel pocket of the canister manifold. Insert
the 3 barrel fittings into the canister manifold. Replace the arm manifold and tighten the screws to finger tight plus ¼ turn. The flange of the arm manifold should touch the surface of the outer arm when the arm manifold is seated
properly.
Complete the installation by placing the nut and ferrule of the Serto fitting 25 mm from the end of the tubing and reassembling the Serto fitting. Be certain that the tube is fully seated in the fitting before bringing the nut down and
tightening. Tighten to finger tight then wrench tighten 1 ¾ revolutions. When replacing the tube, a new ferrule should be used.
P-700 & P-250 Installation

On the P-700 and P-250, the paint isolation line consists of two parts, a long paint isolation line and a short paint isolation line. P-700 isolation line installation is shown in EO-5093-895-002. P-250 isolation line installation is shown in
EO-6263-895-002. The long paint isolation line connects the color changer assembly to the isolation air manifold. The short paint isolation line connects the isolation air manifold to the canister manifold. The lengths of these lines
depend on the robot configuration. Please refer to the table below:
Line Description Pedestal P-700 WB Rail P-700 WB P250 WB

Short Paint Isolation Line Assy EO0593-262-004C EO5093-262-007A EO5093-262-007A
Short Paint Isolation Line Length 380 mm 340 mm 340 mm

Long Paint Isolation Line Assy EO5093-262-004B EO5093-262-007B EO5093-262-007B
Long Paint Isolation Line Length 1500 mm 1730 mm 1730 mm
Table 9-2: P-700 WB and P-250 WB Paint Isolation Line Assemblies
Each line assembly consists of a barrel fitting at each end, a length of 6 x 8 mm FEP tube and 8 o-rings (4 for each barrel fitting). Refer to figures 9-18 and 9-19 for the construction of each line. Assemble each line by installing o-rings
into the glands inside the barrels and o-rings into the glands on the outside of the narrow ends of the barrels. Use hose tool EO-4526-700-008 to mark the engagement depth on the tubing with a permanent marker, then grip the tubing
with hose wrench EO-4526-701-000 and twist the barrel onto the end of the tubing until the end of the barrel is even with the line drawn on the tubing. The line is now ready for installation. Rail P-700 isolation lines connect to the
-407-
isolation manifold EO-5093-310-013. Pedestal P-700 and P-250 isolation lines connect to isolation manifold EO-5093-310-011.
Prepare to remove the isolation line by running a “Superpurge” cycle. All the isolation lines are retained by a barrel clip (EO-5093-310-003) and M6 x 16mm long screw. To remove the barrel, loosen the screw, turn the clip so that it is
no longer retaining the barrel and pull the barrel out. Remove the square cut o-ring (EO9999-200-003I) at the bottom of the barrel pocket.
Install the new line by inserting a new square cut o-ring (EO9999-200-003I) into the barrel pocket and then installing the barrel. Retain the barrel with the clip and tighten the M6 screw.
Route the line through hose guides and clamps as required. NOTE: to route the long isolation line, the arm should be moved to a position where the arm is fully extended at axis 3. When installing a new line, be sure the line has no slack
in this straight arm position before tightening the hose clamp near the FRP, located at the inner arm and outer arm joint.
-408-
9.2.5 Dump Line Components

The tubing and fittings which connect the canister manifold to the paint booth paint waste system are called the “dump line”. This passage is blown dry with compressed air at the end of the “FILL” color change cycle in order to establish
electrostatic isolation. A portion of the dump line system use a special multi layered tubing that is designed to be resistant to electrostatic pin holes. This tubing requires special techniques to prepare its ends for use. Please see EO-
4696-271-000 for instructions on Isocore preparation.
Figure 9-51 EO-6102-270-000 Sheet 1 of 2, STICK DUMP ASM
WARNING
* SEE TABLE extreme care and follow proper lifting
2X EO-6102-270-004
USED TO CLAMP OUTER WARNING
LAYER OF ISOCORE Always disconnect power to the robot
DUMP3 LINE REF you could injure personnel or damage
equipment.
OUTER ABRASION
RESISTANT LAYER EO-4696-260-007 REF UNLESS OTHERWISE NOTED:
REF. SEE EG-00008 FOR LOCTITE REQUIREMENTS
OUTER ABRASION
RESISTANT LAYER
REF.
EXPOSED INNER TUBE BELOW
CORD GRIP
REF.
EO-4696-270-029
CLAMP CORD GRIP ON ISOCORE OUTER JACKET
E
1 x EO-6102-270-002
USED TO CLAMP MIDDLE
LAYER OF ISOCORE EXPOSED CONDUCTIVE LAYER EO-4696-270-019
REF.
EXPOSED INNER TUBE SSHCM005080025G

REF.
EO-4696-270-022
EO-4696-270-017
"A" SSHCM006100025G
MODIFIED ISOCORE
SEE NOTE1
TUBEE075000065O
300 MM
OUTER SHEATH - PLUGS INTO ARM MANIFOLD
[3/4" X 1/2" VITON]
EO-4696-270-027 DETAIL E
2X SSHCM005080010G
SCALE 1 : 5
50.0 SET-UP
AT INSTALLATION
ASSEMBLY PART NO. DESCRIPTION "A" FANUC Part No. Description
EO6102-270-000A STICK DUMP FOR TOP MACHINE EO4696-270-025A PAINT BOOTH GRATES
EO6102-270-000B STICK DUMP FOR SIDE MACHINE EO4696-270-025B SSHCM006100025G M6 X 1.0 X 25mm LG. Glass Filled Nylon Socket Head Cap
NOTES: SSHCM012175030S M12 X 1.75 X 30mm LG. Stainless Steel Socket Head Cap
1. SEE EO-4696-271-000 SHEETS 3-13 FOR
ISOCORE STRIPPING PROCEDURE
[EO-6102-270-000] REV *3
STICK DUMP ASM SHEET 1 OF 2
-409-
Figure 9-52 EO-6102-270-000 Sheet 2 of 2, STICK DUMP ASM
WARNING
WARNING
SSHCM012175020S Always disconnect power to the robot
TORQUE TO 38 N-m (28 FT-LB) before you perform any service or
SSHCM012175030S LOCTITE PER EG-00008 maintenance procedures. Otherwise,
equipment.

20.0°
ADJUSTMENT
2X EO4696-270-204B
EO-6102-270-021
4X SSHCM006100045G
SSHCM012175020S
EO-6102-270-020 TORQUE TO 38 N-m (28 FT-LB)
SSHCM012175030S LOCTITE PER EG-00008
EO-4696-270-018
[EO-6102-270-000] REV *3
STICK DUMP ASM SHEET 2 OF 2
-410-
Figure 9-53 EO-5093-262-000 Sheet 1 of 12, WB COLOR LINE ASSEMBLY
WARNING
WB COLOR LINE ASSEMBLY injure personnel or damge equipment
WARNING
equipment.
FANUC PART NO. DESCRIPTION B C E F SEE SHEETS
EO5093-262-000A 4 Color WB - 20m Color Line Asm EO-5093-262-016 2 4 24 SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO5093-262-000B 8 Color WB - 20m Color Line Asm EO-5093-262-016 4 6 32
EO5093-262-000C 12 Color WB - 20m Color Line Asm EO-5093-262-012 6 8 40
1 & 2-6
EO5093-262-000D 16 Color WB - 20m Color Line Asm EO-5093-262-012 8 10 48
EO5093-262-000E 20 Color WB - 20m Color Line Asm EO-5093-262-012 10 12 56
EO5093-262-000F 24 Color WB - 20m Color Line Asm EO-5093-262-012 12 12 56
EO5093-262-000G 4 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-016 2 6 24
EO5093-262-000H 8 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-016 4 8 32
EO5093-262-000J 12 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-012 6 10 40
1 & 7-11
EO5093-262-000K 16 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-012 8 12 48
EO5093-262-000L 20 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-012 10 14 56
EO5093-262-000M 24 Color WB - 20m Color Line Asm Rail Config. EO-5093-262-012 12 14 56
NOTES:
1. ASSEMBLE THE COLOR LINE BUNDLES USING THE ASSEMBLY FIXTURE (EO-5093-725-000) AS SHOWN ON SHEETS 2-6.
2. TUBES SHOULD RUN APPROXIMATELY PARALLEL TO NEIGHBORING TUBES. TUBES MUST NOT CROSS ONE
ANOTHER. EXCESS LENGTH MUST BE TRIMMED. TUBE LENGTH SHOULD BE SUCH THAT TUBES REMAIN IN FIXTURE
WITHOUT BEING RESTRAINED BY OTHER MEANS. SEE EG-00391.
3. USE LOCTITE PRIMER N AND LOCTITE 222(HDWMO000003367O) ON ALL FASTENERS PER EG-00010
4. DRAW A LINE ACROSS THE PAINT LINES ON BOTH SIDES OF THE CLAMP
5. PAINT LINES CAN NOT TWIST INSIDE JACKET BETWEEN CLAMPS. ALL PAINT LINES MUST BE SQUARED UP AND
ORIENTED WITH THE NATURAL CURL AWAY FROM THE ARM. SEE EG-00391
6. INSTALL USING (2) PLAIN SCREWS (SSHCM006100020C) INCLUDED WITH FIXTURE. PLACE (2) STAINLESS SCREWS
(SSHCM006100020S) IN A BAG AND SECURE TO COMPLETED COLOR LINE ASSEMBLY FOR ATTACHEMENT TO ROBOT.
8. INSTALL USING (4) PLAIN SCREWS (SSHCM012175035C) INCLUDED WITH FIXTURE. TORQUE TO 28Nm [20.6 lbf-ft] PLACE
(4) STAINLESS SCREWS (SSHCM012175035S) AND (2) EO-5093-060-021 IN A BAG AND SECURE TO COMPLETED COLOR
LINE ASSEMBLY FOR ATTACHEMENT TO ROBOT.
10. INSTALL TYRPO00000002O WITH A TENSION OF 31 LBS. A HELLERAMANN TYTON MARK9 WITH A SETTING OF 3 IS
RECOMMENDED.
11. THE VACUUM MANIFOLD SURROGATE IS INSTALLED AS SHOWN FOR ALL CONFIGURATIONS. INSTALL SOLVAIR
BLOCK SURROGATE & COLOR SLICE SURROGATES AS FOLLOWS (SEE SHEET 3):
a. 4 COLOR: (0) COLOR SLICE SURROGATE & SOLVAIR BLOCK SURROGATE IN POSITION 1
b. 8 COLOR: (1) COLOR SLICE SURROGATES & SOLVAIR BLOCK SURROGATE IN POSITION 2
c. 12 COLOR: (2) COLOR SLICE SURROGATES & SOLVAIR BLOCK SURROGATE IN POSITION 3
d. 16 COLOR: (3) COLOR SLICE SURROGATES & SOLVAIR BLOCK SURROGATE IN POSITION 4
e. 20 COLOR: (4) COLOR SLICE SURROGATES & SOLVAIR BLOCK SURROGATE IN POSITION 5
f. 24 COLOR: (5) COLOR SLICE SURROGATES & SOLVAIR BLOCK SURROGATE IN POSITION 6
12. INSTALL COLOR LINES INTO FIXTURES AS SHOWN & CUT TO LENGTH. LOCATION OF FIXTURES AND DEPTH OF
POCKETS SIMULATE LOCATION AND INSTALLATION DEPTHS OF FITTINGS ON COLOR CHANGER ASSEMBLY.
13. CUT PAINT LINE TO LENGTH AS SHOWN.
14. CAP ENDS OF 6mm HOSE USING CAPMO000000099O Standard Hardware Descriptions
15. CAP ENDS OF 10mm HOSE USING CAPMO000000101O
16. CAP ENDS OF BUNDLES USING CAPMO000000107O FANUC Part No. Description
17. LENGTH WILL VARY DEPENDING ON FANUC PART NO. IN ABOVE TABLE SSHCM005080020D M5 X 0.8 X 20mm LG. CL12.9 Dacromet Socket Head Cap
18. BLOW OUT ALL LINES WITH COMPRESSED AIR PRIOR TO INSTALLING HOSE CAPS SSHCM005080060S M5 X 0.8 X 60mm LG. Stainless Steel Socket Head Cap
19. THE COLOR CHANGER ASSEMBLY THAT WILL BE INSTALLED ON THE ROBOT MAY BE USED IN PLACE OF THE SSHCM005080070S M5 X 0.8 X 70mm LG. Stainless Steel Socket Head Cap
SURROGATE ASSEMBLIES. SSHCM005080080S M5 X 0.8 X 80mm LG. Stainless Steel Socket Head Cap
20. CAP ENDS OF 8mm HOSE WITH HOSE CAP (CAPMO000000100O). SSHCM006100016S M6 X 1.0 X 16mm LG. Stainless Steel Socket Head Cap
21. WASH LINE NOT INCLUDED WITH WB COLOR LINE ASSEMBLY. SEE EO5093-545-000B COMMON BELL PROCESS LINE SSHCM006100020S M6 X 1.0 X 20mm LG. Stainless Steel Socket Head Cap
ASSEMBLY.
22. ROUTE HOSES PER EG-00391
[EO-5093-262-000] REV *80

WB COLOR LINE ASSEMBLY SHEET 1 OF 12
-411-
ITEM B
WARNING
WB COLOR LINE ASSEMBLY extreme care and follow proper lifting
CUT BACK OUTER JACKET 15MM INSIDE CLAMPS (24 COLOR SHOWN) components. Otherwise you could
RUN ISOCORE DUMP, AIR LINE AND SOLVENT LINES 2X TYRPO000000002O
LEAVE ENOUGH SLACK SO NOT TIGHT AGAINST ROLLER HEAT STABILIZED TYRAP
GREEN TINTED
WARNING
SEE NOTE 10 before you perform any service or
USE FIXTURE TO DETERMINE TRIM TIE WRAP 8X6 LINES maintenance procedures. Otherwise,
LENGTH AND ARRANGE COLOR LINES. 2PL you could injure personnel or damage
APPROX. MAX. LENGTH = 670mm equipment.
APPROX. MIN. LENGTH = 335mm
AS MEASURED FROM DATUM C 2X TYRPO000000002O LEAVE TOP SPACE OPEN FOR
SEE NOTES 2, 16, 17, & 18 OPTIONAL CASCADE CABLE UNLESS OTHERWISE NOTED:
COIL & TYRAP LOOSE HOSE LENGTH
AE
EO5093-260-010B
F DETAIL F POSITION AS SHOWN
SCALE 1 : 2
AD
COIL REMAINING HOSE UNTIL

REMOVE AND ROTATE GUIDE IF REQUIRED ASSEMBLY IS INSTALLED ON ROBOT
TO KEEP TIE WRAPS ON THE OPPOSITE SIDE SEE NOTE 16
FROM THE TURRET COVER
A
ISOLATION LINE - EO5093-262-004B 419.0 700.0

SEE NOTE 18 & 20
CUT & REMOVE

WASH REF BUNDLE JACKETS HERE
INCLUDED WITH APPLICATOR TO COLOR CHANGER ORIENT NATURAL CURL OF HOSES
HOSE BUNDLE. AWAY FROM FIXTURE IN BOTH DYNAMIC AREAS
SEE NOTE 21
718.4 B 230
L=233.2 BEFORE CLAMP
ISO-CORE DUMPS
185 ABRASION
RESISTANT LAYER
SEE SHEET 6
A
318.5
D C
D AIR
BUNDLE JACKET TO
REMAIN IN THIS AREA
SOL
EO-HOSE-011-012
L=1375mm WASH
ISOLATION LINE
VACUUM EXHAUST
SEE NOTES 14 & 18
ISO-CORE DUMPS
CONDUCTIVE
LAYER
SEE NOTES 15 & 18
SOL2 A
B
SEE SHEET 6 SEE SHEET 5 SEE SHEET 4
C
[EO-5093-262-000] REV *80
-412-
WARNING
WARNING
365.1 before you perform any service or
POSITION 6 maintenance procedures. Otherwise,
309.1 equipment.
6.2 POSITION 5
INSTALL 6mm TUBE 253.1 UNLESS OTHERWISE NOTED:
AS SHOWN POSITION 4 SEE EG-00008 FOR LOCTITE REQUIREMENTS
SEE NOTE 12 PAINT RETURN 23 (PR23) SEE EG-00010 FOR TORQUE SPECIFICATIONS
197.1
POSITION 3
PAINT SUPPLY 23 (PS23)
PAINT RETURN 1 (PR1) 141.1
POSITION 2
13.0 6mm WASH LINE REF
85.1 SEE NOTE 21
PAINT SUPPLY 1 (PS1) POSITION 1
VACUUM MANIFOLD SURROGATE 8mm SOL

WASH LINE SEE NOTES 11
FIXTURE
6mm ISOLATION LINE
12mm AIR SUPPLY
PAINT SUPPLY 2 (PS2) COLOR SLICE SURROGATE

(5) SHOWN 5V SOLVAIR BLOCK SURROGATE
SEE NOTES 11 SHOWN IN POSITION 6
SEE NOTES 11
PAINT RETURN 2 (PR2) 8mm SOL2
PAINT RETURN 24 (PR24)
TOP VIEW FROM SHEET 2
[EO-5093-262-000] REV *80

-413-
WARNING
EO-5093-260-013 Some components are heavy. Use
WARNING
equipment.
SSHCM005080020D UNLESS OTHERWISE NOTED:

QTY "F" - SEE TABLE SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO-5093-260-005
QTY "E" - SEE TABLE
LEAVE FIRST CLAMP OPEN ON

4,8,12,16 & 20 COLOR ASM'S
AIR - EO-HOSE-011-012
L=2100mm
ISO-CORE DUMP
2X EO5093-262-005A
EO-5093-260-011 4X SSHCM006100025S
SEE NOTE 9
EO-HOSE-009G - SEE TABLE 8mm SOL

QTY. "C" - SEE TABLE TUBEM080000025O
SEE NOTE 5 L=2100mm
8mm SOL2
TUBEM080000025O
L=20,000mm
DETACH COMPLETED COLOR LINE ASSEMBLY HERE
FOR INSTALLATION ON ROBOT
EO-5093-260-001 SECTION A-A

ROTATED 90°
4X SSHCM006100016S
TURRET CLAMP
[EO-5093-262-000] REV *80

-414-
WARNING
WARNING
SSHCM005080020D you could injure personnel or damage
QTY. "F" - SEE TABLE equipment.

EO-5093-260-005
QTY "E" - SEE TABLE
4,8,12,16 & 20 COLOR ASM'S


AIR
EO5093-060-006A
EO-5093-060-021
4X SSHCM012175035S PAINT SUPPLY 22 (PS22)

SEE NOTE 8 SOL
ISO-CORE DUMP
PAINT RETURN 4 (PR4) SOL2

SECTION B-B
ROTATED 90°
INNER ARM TO TURRET CLAMP

[EO-5093-262-000] REV *80
-415-
WARNING
3X SSHCM005080070S
3X WSHFM050100010S WARNING
3X NUTHM005080000S Always disconnect power to the robot
equipment.

3X SSHCM005080060S
3X WSHFM050100010S
3X NUTHM005080000S
DETAIL AE
SCALE 1 : 4

4X SSHCM006100016S
SEE NOTE 7 EO-5093-260-004
ISO-CORE DUMPS 2X SSHCM006100020S

WITH ABRASION SEE NOTE 6
AIR SUPPLY DETAIL AD
RESISTANT LAYER
SCALE 1 : 4
WASH REF
SEE NOTE 21
EO-5093-260-015
EO-5093-260-016
WASH REF EO-5093-260-017
ISOLATION LINE
AIR SUPPLY
EO-5093-260-017
ISO-CORE DUMPS
EO5093-262-004B REF WITH CONDUCTIVE
EO-5093-060-019 ISOLATION LINE LAYER
ROTATED 90° 2X EO-5093-260-002

EO-5093-260-016
EO-5093-260-015
2X EO-5093-260-014
SECTION D-D
SECTION C-C SCALE 1:2
ROTATED 90°
[EO-5093-262-000] REV *80

-416-
WARNING
WB COLOR LINE ASSEMBLY TABLE extreme care and follow proper lifting
SEE SHEET 2 RAIL CONFIGURATION components. Otherwise you could

(24 COLOR SHOWN) WARNING

LEAVE TOP SPACE OPEN
FOR OPTIONAL CASCADE CABLE Always disconnect power to the robot
USE FIXTURE TO DETERMINE TRIM equipment.
LENGTH AND ARRANGE COLOR LINES.
APPROX MAX. LENGTH = 670mm EO5093-260-010C UNLESS OTHERWISE NOTED:
APPROX MIN. LENGTH = 335mm POSITION AS SHOWN SEE EG-00008 FOR LOCTITE REQUIREMENTS
AS MEASURED FROM DATUM C SEE EG-00010 FOR TORQUE SPECIFICATIONS
SEE NOTES 2,16,17 & 18
COIL & TYRAP LOOSE HOSE LENGTH
AG
M
AF
DETAIL M
2X TYRPO000000002O SCALE 1 : 2
HEAT STABILIZED TYRAP
GREEN TINTED
SEE NOTE 10
H G
C
WASH REF 419.0 700.0
INCLUDED WITH APPLICATOR
HOSE BUNDLE
SEE NOTE 21 CUT & REMOVE COIL REMAINING
BUNDLE JACKETS HERE HOSE UNTIL
TO COLOR CHANGER ASSEMBLY IS
ORIENT NATURAL CURL OF HOSES INSTALLED ON
AIR (BLUE) AWAY FROM FIXTURE IN BOTH DYNAMIC AREAS ROBOT
EO-HOSE-011-012 718.4 B SEE NOTE 16
L=1450mm L=233.2
ISO-CORE DUMPS (EO5093-262-005B) BEFORE
ABRASION RESISTANT LAYER CLAMP 230
318.5
350
J
K
K SEE SHEET 11
LONG ISOLATION LINE SOL2 HOSE BUNDLE JACKET TO
(EO5093-262-007B) SOL REMAIN IN THIS AREA
WASH
LONG ISLOATION LINE
EO5093-262-007B
SEE NOTES 18 & 20
ISO-COR DUMPS
(EO5093-262-005B)
CONDUCTIVE LAYER
SEE NOTES 15 & 18
J SEE SHEET 11 G SEE SHEET 10
H SEE SHEET 10
[EO-5093-262-000] REV *80

-417-
WARNING
* SEE extreme care and follow proper lifting
TABLE procedures when you install or remove
WB COLOR LINE ASSEMBLY components. Otherwise you could
RAIL CONFIGURATION
(24 COLOR SHOWN) WARNING
( 6.2) before you perform any service or
equipment.
INSTALL 6mm TUBE
AS SHOWN
SEE NOTE 12 UNLESS OTHERWISE NOTED:
13.0
365.1
POSITION 6
309.1
POSITION 5
WASH LINE
FIXTURE 253.1
SCALE 1:2 POSITION 4
197.1
POSITION 3

141.1
POSITION 2
85.1
POSITION 1
6mm WASH LINE REF
PAINTSUPPLY 1 (PS1) SEE NOTE 21
8mm SOL
12mm AIR SUPPLY

VACUUM MANIFOLD SURROGATE
SEE NOTE 11
6mm ISOLATION LINE
5V SOLVAIR BLOCK SURROGATE

COLOR SLICE SURROGATE SHOWN IN POSITION 6
(5) SHOWN SEE NOTE 11
SEE NOTE 11
8mm SOL2
TOP VIEW FORM SHEET 7 PAINT SUPPLY 24 (PS24)
[EO-5093-262-000] REV *80

-418-
WARNING
WB COLOR LINE ASSEMBLY components. Otherwise you could
RAIL CONFIGURATION WARNING
SSHCM005080020D
QTY. "F" - SEE TABLE SHEET 1
(24 COLOR SHOWN) Always disconnect power to the robot
QTY. "E" - SEE TABLE SHEET 1 equipment.

2X EO-HOSE-011-008
L=50MM
AIR (BLUE)
EO-HOSE-011-012
L=2100mm
4,8,12,16 & 20 COLOR ASM'S ISO-CORE DUMPS
3X EO5093-526-005B
EO-5093-260-011
4X SSHCM006100025S
SEE NOTE 9
8mm SOL
TUBME080000025O
EO-HOSE-009G - SEE TABLE SHEET 1 L=2100mm
QTY. "C" - SEE TABLE SHEET 1
SEE NOTE 5 8mm SOL2
TUBME080000025O
L=20,000mm
EO-5093-260-001

TURRET CLAMP
4X SSHCM006100016S ROTATED 90°
[EO-5093-262-000] REV *80

-419-
WARNING
WB COLOR LINE ASSEMBLY injure personnel or damge equipment
RAIL CONFIGURATION WARNING

(24 COLOR SHOWN) before you perform any service or
equipment.
SSHCM005080020D
QTY. "F" - SEE TABLE SHEET 1
EO-5093-260-005
QTY. "E" SEE TABLE SHEET 1

4,8,12,16 & 20 COLOR ASM'S
2X EO-HOSE-011-008
L=50MM

PAINT RETURN 23 (PR23) PAINT SUPPLY 1 (PS1) AIR (BLUE)
ISO-CORE DUMP
PAINT SUPPLY 23 (PS23) PAINT RETURN 3 (PR3)
EO-5093-060-021 PAINT SUPPLY 22 (PS22)

PAINT RETURN 22 (PR22) SOL2 SOL

4X SSHCM012175035S PAINT SUPPLY 4 (PS4) PAINT RETURN 2 (PR2)

SEE NOTE 8 PAINT RETURN 4 (PR4)

INNER ARM TO TURRET CLAMP
ROTATED 90° [EO-5093-262-000] REV *80

-420-
WARNING
WB COLOR LINE ASSEMBLY procedures when you install or remove
3X SSHCM005080080S
3X WSHFM050100010S
RAIL CONFIGURATION injure personnel or damge equipment
3X NUTHM005080000S (24 COLOR SHOWN) WARNING

equipment.

3X SSHCM005080070S
3X WSHFM050100010S
3X NUTHM005080000S
DETAIL AG
SCALE 1 : 4
DETACH COMPLETED COLOR LINE ASSEMBLY HERE EO-5093-260-004

FOR INSTALLATION ON ROBOT ROTATED 90° 2X SSHCM006100020S
SEE NOTE 6
4X SSHCM006100016S
SEE NOTE 7 DETAIL AF
3X EO-5093-260-014 SCALE 1 : 4
EO-5093-262-006
EO-5093-260-015
EO-5093-260-018
3X EO-5093-260-002 EO-5093-260-018
EO-5093-260-015
WASH LINE
WASH LINE
ISOLATION LINE ISOLATION LINE

AIR (BLUE)
ISO-CORE DUMPS
WITH CONDUCTIVE
AIR (BLUE) LAYER
EO-5093-060-019
ISO-CORE DUMPS
WITH ABRASION RESISTANT LAYER SECTION K-K
SECTION J-J
ROTATED 90°
[EO-5093-262-000] REV *80
-421-
WARNING
WARNING
equipment.

EO-6287-262-010
6X NUTHM006100000S
3X SSHCM006100035S
3X WSHFM060012016S
[EO-5093-262-000] REV *80

-422-
Figure 9-65 EO-5093-515-010, DUMP ISOLATION LINE
WARNING
WARNING
equipment.

4X EO9999-200-001F
2X EO-4696-310-039
4X EO9999-200-001E
TUBEM010000014O
450.0
NOTES:
1. TUBING MUST BE CUT SQUARE TO WORK PROPERLY WITH FITTINGS.
2. BARREL FITTING MUST BE REPLACED WHEN TUBING IS REPLACED.
3. LIGHTLY GREASE O-RINGS AND BARREL FITTING WITH ELECTROSTATIC

GREASE EO-4526-050-009 PRIOR TO INSTALLATION
[EO-5093-515-010] REV B
DUMP ISOLATION LINE SHEET 1 OF 1
-423-
Figure 9-66 EO-5093-310-014, DUMP "Y" BLOCK
WARNING
WARNING
equipment.

COVER HOLE WITH

ADHESIVE TAPE TO
RETAIN SEAL
2X SSHCM006100020G
EO-5093-310-010
2X SSHCM006100020G
EO-5093-310-007
2X EO-9999-111-105
EO-5093-310-011
EO9999-200-003I

(EO-4696-310-031)
EO-5093-310-003 SSHCM006100016S M6 X 1.0 X 16mm LG. Stainless Steel Socket Head Cap
SSHCM006100016S
[EO-5093-310-014] REV C2
DUMP "Y" BLOCK SHEET 1 OF 1
-424-
Figure 9-67 EO-5093-310-017, 3 WAY MANIFOLD
WARNING
WARNING
EO-5093-310-015 before you perform any service or
equipment.

3X EO-9999-111-105
3X SSHCM006100016G
EO9999-200-003I
SEE NOTE 1
EO9999-200-001E REF
EO-4696-310-039 REF
2X EO9999-200-001F REF
EO-5093-310-003
EO9999-200-001K SSHCM006100016S
SEE NOTE 1
2X TYRPPLT4HXXXXXX
NOTE:
2X HDWMO000003036O 1. COVER HOLE WITH ADHESIVE TAPE

TO RETAIN SEAL (EO9999-200-003I)
2X SSHCM006100020G
11±1
30.00 SSHCM006100016S M6 X 1.0 X 16mm LG. Stainless Steel Socket Head Cap
[EO-5093-310-017] REV C2
3 WAY MANIFOLD SHEET 1 OF 1
-425-
Figure 9-68 EO-6263-310-001, 2-WAY DUMP MANIFOLD ASM
WARNING
WARNING
equipment.

COVER HOLE
(SEE NOTE 1)
EO-5093-310-007
2X SSHCM006100020G
SSHCM006100016S
EO-5093-310-003
EO-5093-310-005
EO9999-200-003I
2X SSHCM006100020G
(SEE NOTE 2)
2X EO-9999-111-105
BARREL FITTING ~ REF.
NOTE:
1. COVER HOLE WITH ADHESIVE TAPE TO RETAIN SEAL

2. PLACE SCREWS IN PLASTIC BAG & TY-RAP TO BRACKET FOR LATER USE
[EO-6263-310-001] REV
2-WAY DUMP MANIFOLD ASM SHEET 1 OF 1
-426-
Figure 9-69 EO-5093-515-011, DUMP ISOLATION LINE (P-250iB)
WARNING
WARNING
equipment.

TUBEM010000014O
4X EO9999-200-001F
2X EO-4696-310-039
4X EO9999-200-001E
A
580.0
SECTION A-A
NOTE:
1. TUBING MUST BE CUT SQUARE TO WORK PROPERLY WITH FITTINGS
2. BARREL FITTING MUST BE REPLACED WHEN TUBING IS REPLACED
3. LIGHTLY GREASE O-RINGS & BARREL FITTING WITH ELECTROSTATIC
GREASE (EO-4526-050-009) PRIOR TO INSTALLATION
[EO-5093-515-011] REV A
DUMP ISOLATION LINE (P-250iB) SHEET 1 OF 1
-427-
Figure 9-70 EO-4696-271-000-3, Isocore Line Strip Procedure
P500WB: ISOLATION LINE STRIP PROCEDURE

E0-4696-271-000
Sheet 3 of 13
E40431 Rev E
Photo after Completion of Stripping Modifications:
Middle Semi-Conductive
Polyimide Layer is stripped back
to Dim “ B” as shown and folded
over itself to create and
Innermost Layer Electrostatic Stess cone.
10 mm x 7 mm FEP,
high dielectric strength
Outer Abrasion Resistant

Polyurethane Layer is
stripped backe to Dim “ C” as
shown and folded over itself.
EO-HOSE-010H
BULK 3 LAYER ISOLATION
LINE HOSE
I M PORTANT NOTES:
1. M odifications must be per for med with a r azor knife with a new (shar p) blade. A dull blade will incr ease
time and effor t and potentially lead to a nick in the FEP tubing which will r esult in scr appage.
2. Study the following instr uctions befor e star ting! I solation tubing is expensive ($4/Ft.) and even a minor nick
on the FEP tube or semi-conductive layer will detr oy the isolation pr oper ties of the entir e length of line.
3. I f you have not per for med this pr ocedur e befor e, tr y it out on a 2’ sample piece fir st.
-428-

E0-4696-271-000
Sheet 4 of 13
E40431 Rev E
EO-HOSE-010H
BULK 3 LAYER ISOLATION
LINE HOSE Use a razor knife and
Strip back the 3
layers as shown.
Don’ t worry about
nicks yet.
Outer Layer
Abrasion resistant
Polyurethane
Innermost Layer
Middle Layer 10 mm x 7 mm FEP,
Semi-Conductive exposed to clamp in vice
Polyimide
-429-

E0-4696-271-000
Sheet 5 of 13
E40431 Rev E
Use a vice to
clamp/hold the end
of the isocore line.
Clamped end will be
cut back later.
-430-

E0-4696-271-000
Sheet 6 of 13
E40431 Rev E
Use a sharp razor knife and cut a score line

on the outer abrasion resistant sheath. Score
up to the “ C” dimension shown on EO4696-
271-003A-B Sheet 1 plus 75 mm additional.
Length. The clamped end will be trimmed
off and the end of the procedure to achieve
dimension “ C” exactly Be carefull not to cut
thru the outer abrasion resistant layer.
-431-

E0-4696-271-000
Sheet 7 of 13
E40431 Rev E
Use score line and carefully tear

back the outer abrasion resistant
layer.
-432-

E0-4696-271-000
Sheet 8 of 13
E40431 Rev E
Pull the Outer Abrasion Resistant

Layer on top of itself and score
around the perimeter of the tube. Be
careful not to cut thru. Carefully pull
off the excess of the outer layer.
-433-

E0-4696-271-000
Sheet 9 of 13
E40431 Rev E
Completed Outer Layer. The Outer

Layer has been stripped back, folded
over, and excess trimmed off.
-434-

E0-4696-271-000
Sheet 10 of 13
E40431 Rev E
Apply a thin layer of Dielectric

Grease on top of the middle semi-
conductive layer. Gently pull the
middle layer back on top of itself to
the dimension shown on EO4696-
271-003A-B
-435-

E0-4696-271-000
Sheet 11 of 13
E40431 Rev E
Score the outer layer of the folded over

middle layer and gently pull away the
excess. Pull the outer semi-conductive
layer away from the underneath layer
and gently cut away the excess to create
the electrostatic “ stress cone” as shown
in the next slide.
-436-

E0-4696-271-000
Sheet 12 of 13
E40431 Rev E
Bare 10 x 7 FEP with the 2 outer layers stripped

back.
Completed electrostatic stress cone.

Inner semi-conductive layer is stripped back
to Dim “ B” on EO4696-271-003A,B
Outer Abrasion resistant layer is

stripped back to Dim “ C” on
EO4696-271-003A, B
-437-

E0-4696-271-000
Sheet 13 of 13
E40431 Rev E
After stip back, remove clamped end

from vice and trim back to as required
to achieve Dim “ B” and “ C”
-438-
Installation
The dump line is installed differently in the P-500 than it is in the P-700 and P-250.
P-500 Installation:
On P-500, the dump line consists of a length of Isocore tubing (see table), a barrel fitting (EO-4696-310-021), two o-rings (EO9999-200-001E and -001F) and a square-cut o-ring (EO9999-200-003I). Installation procedure for the P-500
dump line is shown in EO-6102-270-000. The barrel fitting connects to one end of the dump line and the other end feeds through the dump stick assembly and is gripped by a special cord grip assembly (EO-4696-270-029).
Description P-500 Top Machine P-500 Side Machine

Modified Isocore Tubing Part Number EO4696-270-025A EO4696-270-025B
Length 4420 mm 4220 mm
Table 9-3: P-500 Dump Line Assemblies
Prepare to remove the dump line by running a “Superpurge” cycle. Then remove the arm manifold (EO-4696-310-002) by removing 7 M6 plastic screws (SSHCM00610040G) from the valve side of the canister manifold and loosening 4
hold down screws on the hose side. Disconnect the 3 barrel fittings from the Canister Manifold.
Next, disconnect the barrel from the dump line. The barrel is threaded on to the tube; remove it by turning it counter-clockwise. Remove the square cut o-ring from the bottom of the barrel socket. Remove the dump line from the process
clamps and stick dump assembly.
Prepare to install the new dump line by installing the o-rings on the barrel. First, install an o-ring into the gland inside the barrel (EO9999-200-001F) and an o-ring into the gland on the outside of the narrow end of the barrel EO9999-
200-001E). Then thread the end of the isocore tubing through insulating tubing and the arm manifold and attach the barrel as follows. Use hose tool EO-4526-700-008 to mark the engagement depth on the tubing with a permanent marker,
then grip the tubing with hose wrench EO-4526-701-000 and twist the barrel onto the end of the tubing until the end of the barrel is even with the line drawn on the tubing.
Install a square cut o-ring into the barrel pocket of the canister manifold. Insert the 3 barrel fittings into the canister manifold. Replace the arm manifold and tighten the screws to finger tight plus ¼ turn. The flange of the arm manifold
should touch the surface of the outer arm when the arm manifold is seated properly.
Route the line through hose guides and clamps as required. Complete the installation by feeding the long stripped end of the isocore tubing into the dump stick and securing the cord grip.
P-700 and P-250 Installation:

On P-700 and the P-250, the dump line consists of two parts: A short length of FEP tubing and several longer lengths of isocore tubing (see chart). P-700 dump line installation is shown in EO-5093-895-002. P-250 dump line
installation is shown in EO-6263-895-002.
-439-
Description Pedestal P-700 Rail P-700 WB P-250 WB

WB
Dump Isolation Line Assy EO4696-270- EO4696-270- EO-5093-515-
025A 025B 011
Dump Isolation Line Length 4420 mm 4220 mm 610 mm
Dump Manifold Assembly EO-5093-310-007 EO-5093-310- EO-6263-310-
(block only) 017 001
Number of Isocore Lines 2 3 2
Modified Isocore Line Part EO5093-526- EO5093-262- EO5093-262-
Number 005B 005B 005B
Overall Length of Isocore Lines 25000 mm 25000 mm 25000 mm
Table 9-4: P-700 Dump Line Assemblies
Prepare to remove the dump isolation line by running a “Superpurge” cycle. The dump isolation line is retained on each end by a barrel clip (EO-5093-310-003) and M6 x 16mm long screw. To remove the barrel, loosen the screw, turn
the clip so that it is no longer retaining the barrel and pull the barrel out. Remove the square cut o-ring (EO9999-200-003I) at the bottom of the barrel pocket.
Install the new line by inserting a new square cut o-ring (EO9999-200-003I) into the barrel pocket and then installing the barrel. Retain the barrel with the clip and tighten the M6 screw.
9.2.6 Waterborne System Parameters

Most waterborne system parameters are unaffected by system maintenance. However, a change in the length of the paint isolation line length might require a change in the isolation volume that is defined on the waterborne setup screen
on the teach pendant.
9.2.6.1 Isolation Volume

U
The Isolation volume is volume of paint that will be drawn into the canister during the “Slow fill” step of the FILL cycle. It should be slightly less than the internal volume of the paint circuit from the color highest number color valve to
the pCAN valve.
There are two methods for determining the isolation volume of the system.
Determining isolation volume by table

Refer to the tables below to determine the recommended isolation volume for your system. Note that the “recommended parameter setting” is 2 cc less than the “theoretical isolation volume” to minimize the chance of solvent
contamination of the canister during the slow fill.
-440-
Number of Colors in Theoretical Isolation Recommended

Color Stack Volume (cc) Parameter Setting
(cc)
1-3 22.7 20.7
4-7 24.3 22.3
8-11 25.9 23.9
12-15 27.5 25.5
16-19 29.1 27.1
20-23 30.7 28.7
Table 9-5: P-500 Isolation Volumes

(cc)
1-4 56.2 54.2
5-8 57.8 55.8
9-12 59.4 57.4
13-16 61.0 59.0
17-20 62.6 60.6
21-24 64.2 62.2
Table 9-6: P-700 Pedestal Isolation Volumes

(cc)
1-4 61.9 59.9
5-8 63.5 61.5
9-12 65.1 63.1
13-16 66.7 64.7
17-20 68.3 66.3
21-24 69.9 67.9
Table 9-7: P-700 Rail and P-250 Isolation Volumes
-441-
Determining isolation volume by direct measurement

The actual isolation volume of the system can be measured directly by filling the paint circuit with liquid, then capturing the part of the liquid between the color valves and the pCAN valve.
Procedure for P-500:

1. Run Superpurge cycle.
2. Remove bell cup from applicator and set up container to collect volume.
3. Fill system with solvent:
a. Open pSOL, pCC, pDUMP2 for 3 seconds.
b. Close all valves.
4. Air push solvent through applicator into container.
a. Open pAIR, pCC, pCAN, pPE, pTRIG until all liquid is collected.
b. Close all valves
5. Measure volume. This volume is the theoretical isolation volume.
Procedure for P-700

1. Run Superpurge cycle.
2. Remove bell cup from applicator and set up container to collect volume.
3. Fill system with solvent:
a. Open pSOL, pCC, pPI, pDUMP2 for 3 seconds.
b. Close all valves.
4. Air push solvent through applicator into container.
a. Open pAIR, pCC, pCAN, pPI, pPAINT, pPE, pTRIG until all liquid is collected.
b. Close all valves
5. Measure volume. This volume is theoretical isolation volume.
-442-

9.3.1 Preventive Maintenance Schedules
Figure 9-81 ET-5093-895-006 Sheet 1 of 4, WB Maintenance Schedules
WARNING
RAM SEAL PISTON components. Otherwise you could
SEALMO000000005O EO-4696-320-017 injure personnel or damge equipment
SCHEDULE C SCHEDULE A
EO-4696-320-001
SEE NOTES 2, 3, AND 4
EO-4696-320-016 WARNING
BUSHING Always disconnect power to the robot
SCHEDULE C maintenance procedures. Otherwise,
CANISTER SLEEVE STATIC SEAL you could injure personnel or damage
EO4696-320-020C EO9999-200-004J equipment.
SCHEDULE D SCHEDULE A
SEE NOTES 2 AND 3 LIGHTLY LUBRICATE
WITH DIELECTRIC GREASE EO-4526-050-009
Valves
4 X EO-5513-003-000
SCHEDULE A
LIGHTLY LUBRICATE WITH
FITEO000001664O DIELECTRIC GREASE EO-4526-050-009
SCHEDULE A INSTALL WITH TOOL EO-5513-700-003
TIGHTEN TO 6.78 Nm [60 in-lbf]
SQUARE CUT O-RING SEE NOTE 1.
TUBEM060000017O 2 X EO9999-200-003I
SCHEDULE A SCHEDULE C
L=30mm
FITCO000001488O
SCHEDULE A
2X SSHCM006100016S
2X EO-5093-310-003
SQUARE CUT O-RING
EO9999-200-003I
SCHEDULE C
EO-5093-310-002
EO-5093-320-000
4 x EO9999-200-001N
SCHEDULE C
EO-5093-310-001
P-700 Manifold shown, maintenance

schedules similar for P-500 components
MAINTENANCE SCHEDULE
NOTES: A REPLACE EVERY 4,000 OPERATING HOURS

1. SEE EB-03516 FOR PAINT VALVE INSTALLATION INFORMATION. B REPLACE EVERY 12,000 OPERATING HOURS
2. APPLY A LAYER OF DIELECTRIC GREASE (EO-4526-050-009) TO THE C REPLACE AS NEEDED
SLEEVE OD PRIOR TO ASSEMBLY
3. DIRT AND CONTAMINATION TRAPPED IN PISTON /SLEEVE CAN LEAD D REPLACE EVERY 10,000 OPERATING HOURS
TO PREMATURE WEAR AND PISTON FAILURE. CLEAN PISTON AND E REPLACE EVERY 30,000 OPERATING HOURS
SLEEVE WITH HENKEL / LOCTITE NATURAL BLUE CLEANER (#82254)
AND CLEAN LINT FREE CLOTH PRIOR TO INSTALLATION.
4. USE EO-4696-700-035 PISTON INSTALLATION TOOL TO LOAD PISTON INTO CYLINDER.
[ET-5093-895-006] REV A
WB Maintenance Schedules SHEET 1 OF 4
-443-
WARNING
VACUUM GENERATOR MANIFOLD EO-5093-515-002 components. Otherwise you could
WARNING
2X EO-5513-003-000 you could injure personnel or damage
equipment.
FITMO000001983O SSHCM006100016S UNLESS OTHERWISE NOTED:

2X FITMO000001982O SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-5093-310-003
2X EO9999-200-001N
PILOT O-RING EO9999-200-003I
4 x EO9999-200-001N VACUUM GENERATOR CARTRIDGE
EO9999-200-001P SCHEDULE C EO-5093-515-005
O-RING SCHEDULE D
EO9999-200-001P EO-5093-515-001
SCHEDULE C O-RING
EO9999-200-001J
SCHEDULE C
EO-5093-515-008
Valves
2 X EO-5513-003-000
SCHEDULE A
LIGHTLY LUBRICATE WITH
DIELECTRIC GREASE EO-4526-050-009
INSTALL WITH TOOL EO-5513-700-003 FITEO000001691O
TIGHTEN TO 6.78 Nm [60 in-lbf]
SEE NOTE 1.
FITEO000001676O
WB COLOR SLICE EO-4657-590-000A

COLOR VALVES
EO-5513-004-000
SCHEDULE E
PILOT O-RINGS
EO9999-200-001N
SCHEDULE C
SQUARE CUT O-RING BETWEEN SLICES

EO9999-200-003I
SCHEDULE C
[ET-5093-895-006] REV A
-444-
WARNING
SPECIAL LINES, PEDISTAL CONFIGURATION components. Otherwise you could
8 x 6 FEP TUBING WARNING

EO-4696-310-029 TUBEM080000026O Always disconnect power to the robot
EO9999-200-001E before you perform any service or
E EO9999-200-001E maintenance procedures. Otherwise,
equipment.

E SECTION E-E
EO-4696-310-036
ISOLATION LINES
LONG LINE: EO5093-262-004B (FEP TUBE 1500 mm LONG)
SHORT LINE: EO5093-262-004C (FEP TUBE 380 mm LONG)
EO-4696-310-036
EO9999-200-001E EO9999-200-001E
F
F 8 x 6 FEP TUBING
TUBEM080000026O
SECTION F-F
DUMP ISOLATION LINE

EO-5093-515-006 (FEP TUBE 575 mm LONG)
NOTES
1. CLEAN INSIDE OF TUBES WITH SOFT CLOTH SOAKED IN ALCOHOL
OR PURGE SOLVENT. TAKE CARE TO NOT SCRATCH INSIDE SURFACE
OF TUBE.
[ET-5093-895-006] REV A
-445-
WARNING
SPECIAL LINES, RAIL CONFIGURATION procedures when you install or remove
4 X EO9999-200-001E TUBEM080000000026O EO-4696-310-038 WARNING

8x6mm FEP TUBING9 Always disconnect power to the robot
G before you perform any service or
equipment.

G EO-4696-310-037 SECTION G-G
ISOLATION LINES 4 X EO9999-200-001E
SHORT LINE: EO5093-262-007A (FEP TUBE 340 mm LONG)

LONG LINE: EO5093-262-007B (FEP TUBE 1730 mm LONG)
2 X EO9999-200-001E
2 X EO9999-200-001F
2 X EO9999-200-001F 2 X EO9999-200-001E
TUBEM010000014O
10x7mm FEP TUBING
H
H SECTION H-H
2 X EO-4696-310-039
DUMP ISOLATION LINE

EO-5093-515-010 (FEP TUBE 450 mm LONG)
NOTES
1. CLEAN INSIDE OF TUBES WITH SOFT CLOTH SOAKED IN ALCOHOL
OR PURGE SOLVENT. TAKE CARE TO NOT SCRATCH INSIDE SURFACE
OF TUBE.
[ET-5093-895-006] REV A
-446-
Figure 9-85 EG-00423 Sheet 1 of 4, Water Heater Temp. Switch Setting Proc.

Title: Water Heater Temp. Switch Setting Proc. EG #: 00423
Water Heater Temperature Switch Setting Procedure

This document contains instructions for setting the lower control temperature for the Waterborne Heater Zone Assembly (EO-5093-896-001x).
Full operational instructions for the temperature switch can be found in the Endress and Hauser Operating Manual for the Thermophant T TTR31 Temperature Switch
General Operation:
The water heater control system is designed to heat solvent at the robot heat exchanger to a temperature above 100 degrees F. The temperature of water supplied to the heat exchanger is controlled by temperature switches on the return manifold. These sensors have
a low set point and a high set point. The factory setting is a low point of 110 deg F and a high set point of 140 deg F.
The control system turns on power to the heater when any manifold sensor drops below the lower set point. Heater power is turned off when any sensor exceeds the upper set point. It is normal for the water temperature to overshoot the upper set point by as much
as 25 degrees F. The temperature switch in the heater enclosure is set to protect the system from overheat conditions. It also monitors the system temperature as a check against a failure of a manifold temperature switch.
-447-

Manifold Temperature
Switches
(Each switch unit
controls temperature
for one robot)
W ater Heate r
Enclosure
Figure 1: Temperature Switch Locations
-448-

Adjustment Procedure:
To change the lower bound of the control range a switch parameter must be changed on each Manifold Temperature Switch (mounted near the hot water return shut-off) and a switch parameter must be changed on the Heater Temperature Switch (inside the water
heater enclosure). FANUC Robotics sets the lower bound at 110 degrees F, but the user may specify a different temperature if desired. For proper operation, the lower bound must not exceed the upper bound (FANUC Robotics Recommends upper bound be set at
140 deg F). The lower bound is controlled by the setting parameter “SP” on the manifold switches and the upper bound is controlled by the setting parameter “RSP” on the manifold switches.
Figure 2: Layout of Temperature Switch Controls
The following procedure is for changing the lower bound of the control range. FANUC Robotics does not recommend changing the upper bound of the control range.
First change the “SP” value for each manifold switch (located outside heater enclosure, one per robot)
Use a pencil, ball point pen or other pointed object to press the indicated keys. When making changes, if you pass a desired parameter, press the key in use (either + or E) to cycle through options (they will repeat).
1. Press E key for longer than 3 seconds to enter the operating menu.
2. Press + key once. Display will show “OUT”
3. Press E key once. Display will show “FUNC”
4. Press E key once. Display will show “SP”.
5. Press the + or – key to adjust the set point for the switch. The value must be less than value of upper bound (RSP2) which is recommended to be set at 140 deg F.
6. When the set point displayed is the value desired press the E key until “OUT” is displayed. Display will show “RSP”, “TSP”, “TRSP” and then “OUT”
7. Press E key for longer than 3 seconds to exit operating menu. Display will ask “SAVE”
8. Press + key once to save.
Verify setting: by repeating step 1 thru 4. Then press + key once to display setting. Use step 6 and 7 to exit.
Next, change the “RSP” value for the heater switch (located inside heater enclosure)
9. Press E key for longer than 3 seconds to enter the operating menu.
10. Press + key once. Display will show “OUT”
11. Press E key once. Display will show “FUNC”
12. Press E key twice. Display will show “RSP”.
13. Press the + or – key to adjust the set point for the switch. The value should be the same as for the “SP” parameter on the manifold switch (set in step 5 above).
14. When the set point displayed is the value desired press the E key twice. Display will show “TSP”. then “TRSP”
15. Press E key once. Display will show “OUT”
16. Press E key for longer than 3 seconds to exit operating menu. Display will ask “SAVE”
17. Press + key once to save.
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Verify setting: by repeating step 9 thru 12. Then press + key once to display setting. Use steps 14 thru 16 to exit.
The table below summarizes the values recommended for each of the parameters used in controlling system temperature.
Setting Summary
Switch Unit Setting Name FANUC Comment
Recommended
Value
Manifold Switch SP 110 deg F Lower bound of control
range
Manifold Switch RSP -50 deg F DO NOT CHANGE
Manifold Switch SP2 300 deg F DO NOT CHANGE
Manifold Switch RSP2 140 deg F Upper bound of control
Range
Heater Switch SP 160 deg F Set above upper bound of

control range (operational
cut-off)
Heater Switch RSP 110 deg F Set at lower bound of
control range
Heater Switch SP2 302.9 deg F DO NOT CHANGE (safety)
Heater Switch RSP2 200 deg F DO NOT CHANGE (safety)
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ParkLok Installation Instructions
The unions are supplied ready for installation
1. Preparation

B. If using EO-9999-111-101 or EO-999-111-103 install o-ring to threaded base of fitting as shown below.
Figure 1: O-ring installation position
C. Apply Loctite #7649 Primer N, or ND-611, to both the block and fitting threads.
D. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the fitting base male threads for both NPT and
BSP threaded fitting bases.
Thread Sealant Directions for Use: Clean and dry parts for best results. Shake well before each use. Remove cap and snip
nozzle tip to desired size. Apply material to parts and assemble. Full cure in 24 hours. Fixture speed with activator <10
minutes.
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Figure 2: Thread Sealant applied to bottom 3 threads of 8mm WB BSPP fitting base as example.
E. Install fitting base into fluid block using an 11/16” socket.

• 10mmx7mm NPT fitting bases to a torque specification of 4.5Nm using a torque wrench.
• 12mmx9mm & 8mmx6mm BSPP fitting bases will bottom out at the bottom of the hex flange on the top of the
fluid block.
Figure 3: 12mm and 8mm BSPP fittings with O-rings Figure 4: 10mm NPT fitting without O-ring
3. Insert tube
A. Use Tool EO-6246-700-002 to mark the correct depth to install the tube in the fitting. Use a permanent marker to mark
tube. Do not score or scribe.
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4. Install ParkLock fitting sleeve and collet

A. Slide the sleeve/collet combination part (EO-9999-111-00x), as seen in Figure 1, up the tube past the depth mark.
Figure 5: Sleeve/ Collet combination part
B. Push the tube onto the barbed fitting base until the tube is flush with fitting base flange, as shown in Figure 3. When
installing the tube over the barbed fitting, grab the tube no more than 3” away from the trimmed end of the tube.
Figure 6: Proper hose installation on fitting base
C. Slide the sleeve/collet combination part down the tube until it rests of the fitting base flange.
D. IMPORTANT! Verify that the sleeve rests above the collet, and the collet rests on the fitting base flange, as seen in
figure below.
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Figure 7: Proper sleeve collet orientation
E. Using Installation Tool EO-9999-111-701, -702, or -703, press on the top of the fitting sleeve, as shown in Figure 4.
Figure 8: fitting sleeve/collet installation
F. Press firmly until the sleeve rests on the collet flange such that no gap exists at the sleeve/collet seam, as shown in the
figure below.
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Figure 9: Proper ParkLok fitting installation example
• There should be no gap between the sleeve/collet seam if properly installed.

• If a gap is visible, repeat step F until no gap is present.
• A gap of at most 0.5mm is acceptable between the fitting base and collet flange.
5. Uninstallation Procedure
A. Using Sleeve Slitting Tool EO-9999-111-704, -705, or -706, press firmly on the top of the fitting sleeve, as shown in
Figure 6.
Figure 10: ParkLok uninstallation
B. Once the uninstall tool has cut through the sleeve, use the T handle to pull the sleeve and collet off of the barbed fitting
base.
C. Remove the tube from the barbed fitting base.
D. Remove the sleeve and collet from the uninstallation tool using a screwdriver or some other tipped device.
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9.4 Troubleshooting
This section provides troubleshooting guidelines for faults generated by the Canister Paint Delivery System. Possible causes and remedies are listed for each fault. The error codes listed below are of the form:
<Equipment 1 fault> / <Equipment 2 fault> “<description>
For example: PNT1-894 WARN / PNT1-906 WARN “Low can Pressure after Fill: %s
The two faults have the same meaning but were posted by different paint robots on this controller.
9.4.1 PNT1-894 WARN / PNT1-906 WARN “Low can Pressure after Fill: %s “
A fill cycle was just completed, but the fluid pressure in the can was found to be lower than the minimum expected.
Cause: Paint supply pressure is inadequate to meet Minimum Fill Torque requirement
Remedy: Check paint supply pressure. Correct paint supply pressure if abnormal. If paint supply pressure is normal, decrease the “Minimum torque after fill” in the setup screen.
Cause: Paint supply valve is not receiving pneumatic signal to open.

Remedy: Check function of paint supply valve solenoid. Replace if necessary.
Cause: Paint supply valve is stuck closed or slow to open.

Remedy: Replace paint supply valve. Take care to shut off paint supply and pilot line before removing valve. Thoroughly clean the valve pocket before installing a new valve.
9.4.2 PNT1-897 PAUS %s / PNT1-909 PAUS %s “HIGH Negative Canister TORQUE”

The maximum compression force on the ball screw has been exceeded. When this occurs, it is usually when the ball screw is extending.
Cause: Paint injector tip in applicator is obstructed.

Remedy: Clean applicator injector tip.
Cause: High paint flow rate is developing too much pressure.

Remedy: Use a larger injector tip to reduce back pressure in system.
Cause: A valve in the paint flow path is stuck closed or slow to open.
Remedy: Replace slow valve.
Cause: Canister mastered position is set incorrectly causing interference between the piston and the canister manifold.
Remedy: Remaster canister axis using visual witness marks as a starting point.
Cause: The main support bearing for the canister ball screw has failed.
Remedy: Replace canister drive assembly. The worn assembly can be rebuilt with a new bearing.
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9.4.3 PNT1-898 PAUS %s / PNT1-910 PAUS %s “HIGH Positive Canister TORQUE”

The maximum tensile force on the ball screw has been exceeded. When this occurs, it s usually when the ball screw is retracting.
Cause: Canister mastered position is set incorrectly causing interference between the piston and the rear of the canister.
Remedy: Remaster canister axis using visual witness marks as a starting point.
Cause: Color change preset for retraction speed during fill is set too high.
Remedy: Change retraction speed to 6000 cc/min or less.
Cause: Electrostatic grease is blocking internal vent passage in canister body. This allows pressure to build as the piston retracts, compressing the air on the back side of the piston.
Remedy: Replace canister assembly. Canister assembly can be rebuilt taking care to keep the vent passage clean of grease.
9.4.4 PNT1-899 PAUS %s / PNT1-911 PAUS %s “Air in Canister detected”

The piston was retracted from the fluid after the Fill sequence and significant torque was still detected on the face of the piston.
Cause: Canister is improperly mastered above the surface of the canister manifold.
Remedy: Remaster the canister using the visual witness marks as a starting point.
Cause: Air is entrained in the paint supply.

Remedy: Check for air infiltration of the paint supply and correct.
Cause: Vacuum generator (if equipped) is not functioning properly.

Remedy: Replace vacuum generator assembly.
9.4.5 PNT1-900 WARN %s / PNT1-912 WARN %s “Low Trigger Torque”

The torque threshold on the canister motor did not reach the minimum torque threshold value during the fill through trigger step of the fill or refill cycle.
Cause: Paint supply pressure is inadequate to meet trigger torque threshold.

Remedy: Check paint supply pressure. Correct paint supply pressure if abnormal. If paint supply pressure is normal, decrease the “Min fill trigger torque” in the setup screen.
Cause: Paint supply valve is not receiving pneumatic signal to open.

Remedy: Check function of paint supply valve solenoid. Replace if necessary.
Cause: Paint supply valve is stuck closed or slow to open.

Remedy: Replace paint supply valve. Take care to shut off paint supply and pilot line before removing valve. Thoroughly clean the valve pocket before installing a new valve.
9.4.6 High Voltage Troubleshooting for the Canister Paint Delivery System
When using the canister paint delivery system with conductive materials such as waterborne paint, high voltage faults may occur that are specifically related to problems with the canister paint delivery system. This section provides
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guidance in diagnosing these kinds of faults.
The following high voltage faults are sometimes related to failures of components in the canister paint delivery system:
• Switched-Off because of dV/dt-FAULT

• Switched-Off because of dI/dt-FAULT
• Switched-Off because of OVERLOAD (Vmin)
• Switched-Off because of OVERLOAD (Imax)
• Estat set point not reached
Procedure 1: Dry Robot Test.
1. Place the robot in a position with the applicator in the center of the cell (i.e. away from grounded metal).
2. Blow down all the following lines for 90 seconds each:
a. To dry the wash line open pAIR, p2T, pBW

b. To dry the paint isolation line and dump line run a super purge then open pAIR, pCC and pDUMP2 ( For P-700 and P-250 also open pPI)
c. To dry the Dump Line open pAIR, p pDUMP2
3. Close all the valves.

4. Enable the e-stats from the control box in “local” mode. Observe the current draw.
Result: If the robot draws more than 15 microamps after this procedure then there is an external ground path that is separate from the fluid delivery lines.
Remedy:
• Replace fabric covers with clean covers

• Check canister compartment for paint or solvent leaks
• Thoroughly clean arm with alcohol or acetone
• Verify that arm drying air is functioning
Result: If the robot does not draw more than 15 microamps after this procedure then issue lies with one of the 3 lines (wash line, dump line, paint line). Use Procedure 2: Line Isolation Test (below).
Procedure 2: Line Isolation Test
1. Run a fill cycle.

2. Turn on the e-stats locally and verify a current draw greater than 15 micro amps. If there current is less than 15 micro amps then stop and repeat procedure 1. Otherwise continue,
3. Turn off the e-stats.
4. Blow down the wash line for 1 minute:
• Open pAIR, p2T and pBW
5. Close all valves.

6. Turn on the e-stats locally, if the current draw is less then 15 micro amps then replace the wash line. If not, continue.
7. Turn off the e-stats
8. Go into the booth and disconnect the paint isolation line from the canister manifold. Carefully tape or tie the end of the line away from the canister manifold. (this removes the ground path through the paint line without drying the
-458-
dump line).
9. Turn on the e-stats locally, if the current draw is less then 15 micro amps then replace the paint isolation line (for P-700: replace both parts, the long one from the color changer and the short one that connects to the canister
manifold. Replace the o-rings also). If the current is greater than 15 micro amps then replace the dump line.

The following spare parts are used to service the Canister Paint Delivery System.
• Paint valve EO-5513-003-000

• 6 x 8 FEP Tubing TUBEM08000000026O
• 7 x 10 FEP Tubing TUBEM010000014O
• Square cut o-ring EO9999-200-003I
• O-ring EO9999-200-001E
• O-ring EO9999-200-001F
• Glass Filled Nylon Screws SSHCM00610040G
• Connection Pin EO-4696-330-022
• Dielectric grease EO-4526-050-009
• Loctite Primer 770 HDWMO000060323
• Loctite 416 HDWMO000056588
• LG-01-02 Grease HDWMO0000041960
-459-
Figure 9-94 EO-5513-003-000, Gen II Paint Valve
WARNING
NOTES: injure personnel or damage equipment
1. REFERENCE EO-4526-060-001 FOR SEAT INTERFACE DIMENSIONS.

2. EO-5513-003-000 IS A PURCHASED ASM. HOWEVER, ALL COMPONENTS WARNING
MUST BE MADE TO FRA DRAWING SPECIFICATIONS. Always disconnect power to the robot
equipment.

[EO-5513-003-000] REV D
SHEET 1 OF 1
-460-
Figure 9-95 EO-4696-330-022, CONNECTION PIN
WARNING
WARNING
equipment.

[EO-4696-330-022] REV A
CONNECTION PIN SHEET 1 OF 1
-461-

The following tools are required to perform maintenance on the Canister Paint Delivery System.
• Paint valve tool EO-5513-700-003

• 6 mm Allen wrench
• 8 mm Allen wrench
• Hose Tool EO-4526-700-008
• Hose Wrench EO-4526-701-000
• Tube cutter
• Small flat head screwdriver
• Piston Install Tool EO-4696-700-035
-462-
Figure 9-96 EO-5513-700-003, VALVE TOOL
WARNING
WARNING
equipment.

EO-58513-700-003
[EO-5513-700-003] REV C
VALVE TOOL SHEET 1 OF 1
-463-
Figure 9-97 EO-4526-700-008, HOSE DEPTH TOOL
WARNING
WARNING
equipment.

NOTE:
TO MARK PROPER DEPTH OF HOSE INTO FITTINGS.
INSERT COMPLETLY INTO PROPER HOLE AS MARKED.
MARK TUBING FOR DEPTH WITH A LINE AS CLOSE
TO TOP TOOL AS POSSIBLE.
[EO-4526-700-008] REV A
HOSE DEPTH TOOL SHEET 1 OF 1
-464-
Figure 9-98 EO-4526-701-000, HOSE WRENCH ASM
WARNING
WARNING
equipment.

EO-4526-701-001
SFHCE004040038P (4)
A
EO-4526-701-001
HDWMO00005617O A
SECTION A-A

SFHCE004040038P #4-40 X 3/8 LG. Plated Steel Socket Flat Head Screw
[EO-4526-701-000] REV A
HOSE WRENCH ASM SHEET 1 OF 1
-465-
Figure 9-99 EO-4696-700-035, PISTON SEAL INSTALL TOOL
WARNING
WARNING
equipment.

[EO-4696-700-035] REV A
PISTON SEAL INSTALL TOOL SHEET 1 OF 1
-466-
-467-
MARMCP7AP07071E REV. C 10 Color Changer – Canister
-468-
10 Color Changer – Canister MARMCP7AP07071E REV. C
10 COLOR CHANGER – CANISTER

10.1 Overview
The color changer enables the robot to switch between colors without color contamination, and provides a cleaning function to clean the paint lines from the color changer through the applicator. The Color Changer consists of the SolvAir
module, at least one color module, an end block.
Figure 10-1 EO-5093-510-002, WB COLOR STACK ARM ASM
WARNING
2X FITTO000000838O - AIR procedures when you install or remove
FITRO000000534O injure personnel or damge equipment
EO-HOSE-011-012
FITCO000001345O - SOL LENGTH = 365mm
WARNING
p2T 3X EO-4696-522-000 before you perform any service or
EO-HOSE-011-004 SEE NOTES 10 & 11 maintenance procedures. Otherwise,
LENGTH = "C" EO-HOSE-011-012 you could injure personnel or damage
SEE NOTE 9 L=85MM equipment.
FITCO000001519O
A FITRO000000489O - WASH UNLESS OTHERWISE NOTED:
pCC EO-5093-510-014 FITCO000001330O
EO-HOSE-011-004 SEE EG-00008 FOR LOCTITE REQUIREMENTS
LENGTH ="C" EO-4657-590-005 SEE EG-00010 FOR TORQUE SPECIFICATIONS
SEE NOTE 9 pCOLOR - ODD
FITCO000001345O
- SOL2 EO-HOSE-011-004
pAIR LENGTH = 200 MM
EO-HOSE-011-004 QTY 'A' IN TABLE
LENGTH = "D" SEE NOTE 8
SEE NOTE 9
pCOLOR - EVEN
EO-HOSE-011-004
LENGTH = 300 MM
QTY 'B' IN TABLE
SEE NOTE 8
AIR
EO-HOSE-011-006
32X FITCO000001381O REF. LENGTH="F"
EO-5093-150-005 REF 4X SSHCM006100050S

SEE NOTE 6 MOUNTING SCREWS
SSHCM004070008S TORQUE TO 1 N-m
EO-4696-510-003 SEE NOTE 7
GROUND STRAP FOR VLVCO000000184O
SOLV-AIR
LOOP AND TY-RAP
EXCESS WIRE EO-HOSE-011-006
LENGTH=40mm
NOTES: EO-5093-150-001 REF EO-5093-515-002

SEE NOTE 6
1. 24 WB COLOR STACK ASM SHOWN.
2. COLOR STACK ASM. AVAILABLE WITH 4, 8, 12, 16, 20 AND 24 COLORS. 8X SCRMO000000041O
SEE TABLE FOR SPECIFIC CONFIGURATIONS.
3. N/A.
4. COLOR PILOT LINE - ODD: (2) PER COLOR SLICE
5. COLOR PILOT LINE - EVEN: (2) PER COLOR SLICE pSOL
6. TAG KIT: EO-5093-150-004 INCLUDES REQUIRED TAGS EO-HOSE-011-004
LENGTH = "D" 4X FITEO000001696O
7. PLACE THESE SCREWS IN A PLASTIC BAG AND TYRAP TO COLOR
STACK ASSEMBLY FOR LATER USE. SEE NOTE 9 pVAC
8. CAP BUNDLES OF (4) PILOT LINES WITH HOSE CAP (CAPMO000000101O) EO-5093-150-002 REF EO-HOSE-011-004
9. CAP 4mm LINES WITH HOSE CAP (CAPMO000000098O) SEE NOTE 6 EO4657-590-000C LENGTH = 95mm
10. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK COLOR SLICE ASM. SEE NOTE 9
VALVE. DO NOT PUT TEFLON TAPE ON THE 1ST 3 LEADING THREADS pSOL2
EO-HOSE-011-004 SEE NOTE 2 EO5093-515-009X REF
OF THE MALE NPT.
LENGTH = "E" EXHAUST TUBE
11. USE TEFLON TAPE (TAPEO000000003O) ON 1/4 MALE NPT OF SERTO SEE NOTE 9
FITTING(s) FOR CHECK VALVE. DO NOTE PUT TEFLON TAPE ON THE 1ST SEE PDL
3 THREADS OF THE MALE NPT.
PLGMO000000015O
DETAIL A pVAIR
12. DO NOT USE LAREGE HEX TO TIGHTEN CHECKVALVE. SEE EG-00492. EO-5093-150-010
SCALE 1 : 4 EO-HOSE-011-004
LENGTH = 170mm
SEE NOTE 9
510 Assembly No. Description

# of # of Color Slices QTY QTY QTY QTY QTY QTY QTY
colors (EO4657-590-000C) 'A' 'B' 'C' 'D' 'E' 'F' 'G'
EO5093-510-002A WB CC ASM: Rec, 4 clr 4 1 2 2 580 540 95 280 0 Standard Hardware Descriptions
EO5093-510-002B WB CC ASM: Rec, 8 clr 8 2 4 4 524 484 151 336 0 FANUC Part No. Description
EO5093-510-002C WB CC ASM: Rec, 12 clr 12 3 6 6 468 428 207 392 0 SSHCM004070008S M4 X 0.7 X 8mm LG. Stainless Steel Socket Head Cap
EO5093-510-002D WB CC ASM: Rec, 16 clr 16 4 8 8 412 372 263 448 0
EO5093-510-002E WB CC ASM: Rec, 20 clr 20 5 10 10 356 316 319 504 0
EO5093-510-002F WB CC ASM: Rec, 24 clr 24 6 12 12 300 260 375 560 0
[EO-5093-510-002] REV *29
WB COLOR STACK ARM ASM SHEET 1 OF 1
-469-
Figure 10-2 EO-6102-510-005, P500iA WB COLOR STACK ASM
WARNING
FITCO000001372O (1) procedures when you install or remove
AIR SUPPLY FROM HEAT XCHANGER components. Otherwise you could
SEE NOTE 4
EO-4696-522-000 (3) WARNING

CHECK VALVE - SEE NOTES 3, 4 & 5 Always disconnect power to the robot
equipment.
FITCO000001345O (1)
SOLVENT SUPPLY FROM FITCO000001331O (1) UNLESS OTHERWISE NOTED:
HEAT XCHANGER CONNECT TO SOL2 SUPPLY SEE EG-00008 FOR LOCTITE REQUIREMENTS
SEE NOTE 4 (FITCO000001345O WHEN SOL2 IS BYPASSED) SEE EG-00010 FOR TORQUE SPECIFICATIONS
PLGMO000000033O
FITCO000001330O (1) FITCO000001534O
FITRO000000489O (1) SEE NOTE 6. EO4657-590-000C
FITEO000001535O (1) COLOR SLICE ASSY (SEE TABLE)
CONNECT TO 2T LINE CONNECT TO DUMP3 LINE
EO-4657-590-002 (1)
SSHCM006100050G (4)
EO4657-590-005
5 VALVE SOLVAIR
FITCO000001345O (1)
# of Color Slices NOTES:

510 Assembly No. Description # of colors (EO4657-590-000c)
1. 23 WB COLOR STACK ASM SHOWN.
EO6102-510-005A WB CC ASM: Rec, 3 clr 3 1 2. COLOR STACK ASM. AVAILABLE WITH 3, 7, 11, 15, 19 AND 23 COLORS.
SEE TABLE FOR SPECIFIC CONFIGURATIONS.
EO6102-510-005B WB CC ASM: Rec, 7 clr 7 2 3. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK
VALVE. DO NOT PUT TEFLON TAPE ON THE 1ST 3 LEADING THREADS
EO6102-510-005C WB CC ASM: Rec, 11 clr 11 3 OF THE MALE NPT.0
EO6102-510-005D WB CC ASM: Rec, 15 clr 15 4 5. DO NOT USE LARGE HEX TO TIGHTEN CHECK VALVE. SEE EG-00492.
6. REPLACE EXISTING FITTING AT THIS LOCATION WITH FITCO000001534O.
EO6102-510-005E WB CC ASM: Rec, 19 clr 19 5 7. FOLLOW INSTRUCTIONS INS EG-00421 OR SERTO FITTING
INSTALLATION.
EO6102-510-005F WB CC ASM: Rec, 23 clr 23 6 8. FOLLOW INSTRUCTIONS IN EG-00573 FOR PARKER PARKLOK FITTING
INSTALLATION. Standard Hardware Descriptions
[EO-6102-510-005] REV *13

P500iA WB COLOR STACK ASSY SHEET 1 OF 1
-470-

10.2.1 Five Valve SolvAir Module
Figure 10-3 EO-4657-590-005, SOLV/AIR 5 VALVE ASM
WARNING
WARNING
equipment.
5X FITMO000001982O UNLESS OTHERWISE NOTED:

5X EO9999-200-001N
2X EO-4657-502-002
5X EO-5513-007-000
EO9999-200-003I
NOTES:
1. SEE EB-03516 FOR PROPER VALVE INSTALLATION

2. FITTING COMES WITH COLLET, CARTRIDGE, AND O-RING. DO NOT USE THE CARTRIDGE AND O-RING.
3. LUBRICATE O-RINGS WITH A THIN COAT OF DIELECTRIC GREASE (EO-4526-050-009) PRIOR TO INSTALLATION [EO-4657-590-005] REV K
SOLV/AIR 5 VALVE ASM SHEET 1 OF 1
-471-
The 5 Valve Solve Air module allows purge solvent and purge air to be simultaneously delivered to the Color Changer. This mechanical feature eliminates the need for added programming steps typically alternating a solvent then an air
valve several times during a color change cleanout cycle. A secondary outlet, 2T is used for routing solvent, air, or aerated SolvAir mix to the applicator.
The SolvAir module is located at the rear of the Color Changer. It consists of five paint valves (EO-5513-002-000) to control the AIR, SOL, 2T, SOL2, and DUMP3 valves, as well as the SolvAir endcap (EO-4657-501-003)
SolvAir solvent regulator flow rates:
SPECIFIC GRAVITY = 1.0 (water)

0.38 – 0.42 gpm = 24.0-26.5 cc/s
SPECIFIC GRAVITY = 0.9

0.40 – 0.44 gpm = 25.3-27.9 cc/s
SPECIFIC GRAVITY = 0.8 (Methyl Isobutyl Ketone)

0.42 – 0.47 gpm = 26.8-29.6 cc/s
The SolvAir Module connects to the color module using 2 color manifold screws (EO-4657-502-002) using a 6mm Allen wrench.
The SolvAir Module connects to the arm using 2 screws (SSHCM006100050C).
The paint valves screw into the SolvAir module using the Valve Tool as shown in the Special Tools Section. See EB-03516.
<caution: Do not remove Solv-Air flow control module.>
The pilot lines for the AIR, SOL, CC, 2T, SOL2, and DUMP3 valves plug into 5 fittings, FITMO000001982O.
Check valves (EO4696-522-000) are attached to the air inlet and solvent inlet ports.
The SolvAir module connects to the color module through an outlet port. The outlet port is surrounded by a face seal o-ring (EO9999-200-003C)
Caution: It is crucial to the operation of the SolvAir valve that the solvent inlet pressure is at least 10 PSI higher than the air inlet pressure or the unit will not work properly and result color carry-over or high voltage faults.
-472-
10.2.2 Color Module – Recirculating

Figure 10-4 EO-4657-590-000 Sheet 1 of 5, WB VALVE BLOCK
WARNING
FITTING FOR 8MM TUBE (SEE TABLE)
WARNING
4 x FITMO000001982O COLLET maintenance procedures. Otherwise,
4 x EO9999-200-001N O-RING you could injure personnel or damage
equipment.
EO9999-200-001H
EO9999-200-001H SEE EG-00010 FOR TORQUE SPECIFICATIONS
FITTING FOR 12MM TUBE (SEE TABLE) EO9999-200-003I

(4) PILOT FOR PAINT VALVE
4mm PUSH TO LOCK
TUBE FITTING EO-4657-502-002
(2) LOCATING PINS

4.60
EO4657-590-000A NOTES:
1. NA
2. NA
3. NA
4. THIS ASSMBLY INCLUDES COMPONENTS AS SHOWN AND AS LISTED IN
TABLE
5. NA
6. NA
7. NA
EO-5513-004-000 EO4657-590-000C 8. FOLLOW INSTRUCTIONS IN EG-00573 TO INSTALL EO-9999-111-003 AND
EO-9999-111-001
9. FOLLOW INSTRUCTIONS IN EG-00421 TO INSTALL SERTO FITTINGS
KATES "A" 9. SPARE PART NUMBER FOR COLLET/SLEEVE OF FITTING EO-9999-111-101

FANUC PART NO. PART NO. DESCRIPTION FITTING PART NO. IS EO-9999-111-002.
EO4657-590-000A FR41 6 MM THRU PORT, W- 12/9:EO4657-590-003C, 8/6:EO4657-590-003A
FITTINGS 10. SPARE PART NUMBER FOR COLLET/SLEEVE OF FITTING EO-9999-111-103
6 MM THRU PORT, NO IS EO-9999-111-004.
EO4657-590-000B FR45 FITTINGS
12/9:EO-9999-111-003, -004
6MM THRU PORT W BARB w/ EO9999-200-001H o-ring
EO4657-590-000C FITTINGS 8/6:EO-9999-111-001, -002
w/ EO9999-200-001H o-ring *SEE NOTE 8
[EO-4657-590-000] REV H2
WB VALVE BLOCK SHEET 1 OF 1
-473-
The Color Module (EO4657-590-000A) is the point where the paint enters the Canister color system. It consists of 4 air piloted paint valves. Air pilots the valves to open, and a spring closes the valve shut. The valves that are used are
EO-5513-004-000.
Each color valve has a supply and return paint circulation line, connected by a plastic fitting. The Supply line uses a 12mm plastic fitting (FITCO000001365O), and the return line uses an 8mm plastic fitting (FITCO000001371O).
Install the hex fittings flush to block face.
The color block does not connect to the arm. Instead the color block connects to the adjacent blocks using 2 screws (EO-4657-502-002) with a 6mm Allen wrench. The fluid passage connects to the adjacent block with an outlet
surrounded by a face seal o-ring (EO9999-200-003C)
Depending on the number of colors being used, the following block could be another recirculating Color Module or an end block if no more colors are being used.
-474-
10.2.3 Non-Recirculating Color Module

Figure 10-5 EO-4657-590-006, WB NON-RECIRCULATING VALVE BLOCK
WARNING
FITTING FOR 12MM TUBE (SEE TABLE) extreme care and follow proper lifting
WARNING
equipment.
EO-9999-200-001H UNLESS OTHERWISE NOTED:

4 X FITMO000001982O COLLET
4 X EO9999-200-001N O-RING
EO-4657-502-002
SEE TABLE
EO4657-590-006C
EO4657-590-006A EO9999-200-003I
EO-5513-004-000
NOTES:
1. SPARE PART NUIMBER FOR COLLET / SLEEVE OF FITTING EO-9999-111-103 IS EO-9999-111-004
FANUC PART NO. DESCRIPTION FITTING PART NO.
EO4657-590-006A 6 MM THRU PORT, W- FITTING FOR 12MM TUBE:EO4657-590-003C
FITTINGS
EO4657-590-006B 6 MM THRU PORT, NO
FITTINGS
EO4657-590-006C 6MM THRU PORT, BARBED FITTING FOR 12 MM TUBE: EO-9999-111-103
FITTINGS
[EO-4657-590-006] REV *2
WB NON-RECIRCULATING VALVE BLOCK SHEET 1 OF 1
-475-
The Color Module (EO4657-590-006A) is the point where the paint enters the Canister color system. It consists of 4 air piloted paint valves. Air pilots the valves to open, and a spring closes the valve shut. The valves that are used are
EO-5513-004-000.
Each color valve has a supply paint circulation line, connected by a plastic fitting (FITCO000001365O). Install the hex fittings flush to block face.
The color block connects to the following block using 2 screws (EO-4657-502-002) with a 6mm Allen wrench. The fluid line connects to the following block with an outlet surrounded by a face seal o-ring (EO9999-200-003C)
Depending on the number of colors being used, the following block could be another non circulating Color Module or a pressure regulator if no more colors are being used.
-476-
10.2.4 End Block

The End block is located at the bottom of the color valve assembly and routes the paint flow to the canister manifold.
Figure 10-6 EO4657-590-002A, End Block
WARNING
WARNING
equipment.

EO-4657-590-002 SEE EG-00008 FOR LOCTITE REQUIREMENTS
2X SSHCM006100050C
FITCO0000013290
[EO4657-590-002A] REV A
End Block SHEET 1 OF 1
-477-
10.2.5 Maintenance and Repair

Figure 10-7 EO-4657-590-003, BSPP Fitting
WARNING
* SEE CHART procedures when you install or remove
WARNING
equipment.

EO9999-200-001H O-RING
PART NUMBER DESCRIPTION TUBE SIZE WAKates #

EO4657-590-003A BSPP Fitting for 6 MM x 8 MM Hose 8 x 6 MM FR50-1
EO4657-590-003B BSPP Fitting for 10 MM x 7 MM Hose 10 x 7 MM FR50-2
EO4657-590-003C BSPP Fitting for 12 MM x 9 MM Hose 12 x 9 MM FR50-3
[EO-4657-590-003] REV *2
BSPP Fitting SHEET 1 OF 1
-478-
Figure 10-8 EO-9999-111-101, PARKER 6x8MM 1/4BSPP FITTING ASSY
WARNING
WARNING
equipment.

EO-9999-111-002
EO-9999-111-001
EO9999-200-001H
ASSEMBLED APPEARANCE
[EO-9999-111-101] REV A
PARKER 6x8MM 1/4BSPP FITTING ASSY SHEET 1 OF 1
-479-
Figure 10-9 EO-9999-111-103, PARKER 9X12MM 1/4BSPP FITTING ASSY
WARNING
WARNING
equipment.

EO-9999-111-004
EO-9999-111-003
EO-999-200-001H
[EO-9999-111-103] REV A
PARKER 9X12MM 1/4BSPP FITTING ASSY SHEET 1 OF 1
-480-
Figure 10-10 EO-9999-111-105, PARKER 7x10MM 3/8NPT FITTING ASSY
WARNING
WARNING
equipment.

EO-9999-111-006
EO-=9999-111-005
[EO-9999-111-105] REV A
PARKER 7x10MM 3/8NPT FITTING ASSY SHEET 1 OF 1
-481-
Figure 10-11 EG-00590 Sheet 1 of 3, PARKER SS FITTING INSTALLATION GUIDELINE

Title: Parker Stainless Fitting Installation EG EG #: EG-00590
Parker Stainless Fitting Installation Guideline

1. Preparation

B. Apply Loctite #7649 Primer N, or ND-611, to any plastic female threads that will receive the stainless steel fitting.
Figure 1: Apply Primer to any plastic female threads, like the check valve female threads.
C. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the fitting base male threads for both NPT and BSP
threaded fitting bases.
Thread Sealant Directions for Use: Clean and dry parts for best results. Shake well before each use. Remove cap and snip nozzle tip to
desired size. Apply material to parts and assemble. Full cure in 24 hours. Fixture speed with activator <10 minutes.
D. Install fitting base into female thread.

• When installing fitting base into a check valve, use a wrench on the upper hex of the check valve to hold the check valve
secure.
C:/egs/eg00192.doc
This material is the exclusive property of FANUC Robotics Corporation and must be returned to FANUC immediately upon request.
This material and the information illustrated herein may not be reproduced, copied, used or transmitted in whole or in part in any way
without the consent of FANUC
-482-

Figure 2: Use a wrench on the upper hex of a check valve to hold the check valve secure during fitting installation.
• 10mm ¼”NPT fitting bases install to a torque specification of 5Nm using a torque wrench and a fitting installation adapter
fiflfl fl ̦ ̦ ̦ ̦ ̦ ̦ ̦ ̦fl .
• 8mm ¼”NPT fitting bases install to a torque specification of 5Nm using a torque wrench and a 5/8” socket.
3. Slide the plastic sleeve, fitting nut, and the single ferrule over the tube as shown in Figure 3, making sure the ferrule wedge is pointing
towards the end of the tube and away from the fitting nut.
Figure 3: Make sure that the ferrule wedge is pointing towards the cut end of the tube
C:/egs/eg00192.doc
-483-

4. Sit the cut end of the tube on the fitting base and slide the ferrule and the nut until they meet the threads of the fitting base.
5. Tighten the fitting nut hand tight plus 1 ¼ turn or to a torque of 4.9Nm, whichever is greater..
• When installing fitting base into a check valve, use a wrench on the upper hex of the check valve to hold the check valve secure as
shown in Figure 4.
• For 10mm Parker Stainless Steel fittings, use fiflfl fl ̦ ̦ ̦ ̦ ̦ ̦ ̦ ̦fl to tighten the fitting nut.
• For 8mm Parker Stainless Steel fittings, use fiflfl fl ̦ ̦ ̦ ̦ ̦ ̦ ̦fl to tighten the fitting nut.
6. Slide the plastic sleeve over the fitting assembly and place a tie wrap around the hose just past the top of the plastic sleeve to hold the
sleeve in place.
C:/egs/eg00192.doc
-484-
Figure 10-14 EG-00594 Sheet 1 of 2, PARKER Parklok Check Valve Installation GUIDELINE

Title: Parker Parklok Check Valve Installation Guideline EG #: EG-00594
Parker Stainless Fitting Installation Guideline

1. Preparation

B. Apply Loctite #7649 Primer N, or ND-611, to any plastic female threads that will receive a fitting.
Figure 1: Apply Primer to any plastic female threads, like the check valve female threads.
C. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the fitting base male threads for both NPT and BSP
threaded fitting bases.
D. Install fitting base into female thread.

• When installing fitting base into a check valve, use a wrench on the upper hex of the check valve to hold the check valve
secure.
C:/egs/eg00192.doc
-485-
Figure 10-15 EG-00594 Sheet 2 of 2, PARKER Parklok Check Valve Installation GUIDELINE

Title: Parker Parklok Check Valve Installation Guideline EG #: EG-00594
• Install 10x7mm and 8x6mm ¼” NPT fitting bases to a torque specification of 3.5Nm using a torque wrench and an 11/16”
deep well socket
3. Once the threaded fitting base is installed in the check valve body, follow EG-00573 Step 3 to install the tube and sleeve/collet combination to
the threaded fitting base.
C:/egs/eg00192.doc
-486-
Figure 10-16 EG-00595 Sheet 1 of 3, PARKER RIGHT ANGLE ADAPTER KIT INSTALLATION GUIDELINE

Title: Parker Right Angle Adapter Kit Installation Guideline EG #: EG-00595
Parker Right Angle Adapter Kit Installation Guideline
Figure 1: 90° Parker adapter and 1/4" BSPP fitting
1. Install 90° into block

A. Make sure that all male and female threads are free of thread sealant or other debris. Clean plastic components with acetone.
B. Apply Loctite #7649 Primer N, or ND-611, to any plastic male and female threads.
C. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the ¼” NPT male threads on the 90° adapter (EO-9999-
115-001).
D. Thread 90° adapter into the block such that the ¼” BSPP female thread is facing the top of the color blocks as shown in Figure 1.
C:/egs/eg00192.doc
-487-

Figure 2: Parker 90° adapter kit (EO-9999-115-001)
2. Install fitting base into female thread of the right angle adapter.
A. Place the o-ring (EO9999-200-003I) into the bottom of the ¼” BSPP threaded hole in the 90° adapter.
B. Place the o-ring (EO9999-200-001J) over the threads on the base of the fitting (EO-9999-111-011).
C. Apply Loctite #7649 Primer N, or ND-611, to any plastic male and female threads.
C:/egs/eg00192.doc
-488-

D. Apply Loctite #554, or ND-446, Thread Sealant to the bottom 3 threads of the ¼” BSPP threaded fitting base (EO-9999-111-011).
E. When installing the fitting base into the 90° adapter, 6mmx4mm ¼” BSPP fitting bases will bottom out at the bottom of the hex flange
on the face of the 90° adapter.
3. Once the threaded fitting base is installed in the check valve body, follow EG-00573 Step 3 to install the tube and sleeve/collet combination to
the threaded fitting base.
C:/egs/eg00192.doc
-489-
10.2.6 Paint Valve Maintenance

1. Inspect all paint valves during weekly maintenance for leaks and/or malfunction, using procedures found in EB-03516.
2. The paint valve is not a field serviceable unit.
3. Paint valves must be replaced as a whole.
4. Replaced a damaged valve with a new valve.
5. Discard damaged paint valves promptly – do not store them.
6. Life of a paint valve under normal operation is 2,000,000 cycles.
7. Replace paint valves according to the following schedule from ET-5093-890-006 using procedures found in EB-03516.
Replace
Paint Valve Avg Cycles after hours No.of years with No. of years with
Location per Job in use. 1 hour shift 2 hour shift
Color Stack 1 30000 10 YRS 2 QTRS 5 YRS 1 QTR

Solv-Air Block 2 15000 5 YRS 1 QTR 2 YRS 2 QTR
Pump Block 2 15000 5 YRS 1 QTR 2 YRS 2 QTR
Applicator 3 10000 3 YRS 2 QTRS 1 YR 3 QTR
Table 10-1: Wear part replacement schedule
10.2.7 SolvAir Module

1. Replace valves in the SolvAir Module after 15,000 hours in use.
2. Replace check valves annually, as suggested in ET-5093-890-006.
10.2.8 Color Module

1. Inspect color module and valves during weekly maintenance.
2. Replace valves in color module after 30,000 hours in use.
Troubleshooting Paint Valves
1. Turn off all paint and solvent supplies to the color changer manifold. Relieve all potentially entrapped paint, solvent, or air pressure in the system undergoing maintenance.
2. Inspect valves for fresh fluid in the weep holes.
3. Disconnect pilot lines.
4. Remove the paint valve in question. Use the color valve tool EO-5513-700-003 or a 17mm wrench and grasp the hex head surfaces of the valve.
5. It may be necessary to remove paint lines in order to clean valve socket.
6. Clean the interior of the valve socket with solvent. Inspect the stainless steel valve seat for any damage.
-490-
7. Thoroughly clean valve socket and pilot passage before installing valve.
8. Discard the damaged valve and replace with a new one. Insure that the new valve is seated properly by observing the stem of the actuator. It should be flush with the top of the valve. If the valve is over tightened the stem will be
protruding from the top of the valve. If the stem is recessed into the valve, the valve is not tightened sufficiently.
If no SolvAir is produced when requested, such as when cleaning the shape air nozzles or cleaning lines during a color change, check the following items:
1. Verify that the SOL, AIR, and 2T valves actuate by observing the valve poppets. When the valve is actuated the stem should protrude slightly from the top of the valve. If the stem is recessed into the valve body without a signal
applied, the valve is not seated properly, or the actuator/poppet is defective. If the valve is not actuating properly, replace the failed valve using procedures found in EB-03516.
2. Verify that the solvent pressure is at least 10 PSI above supply air pressure.
10.3.2 Color Module

Typically only two problems arise with this color valve:
1. Leakage out the weep port or through a worn valve that is not seating properly. If leakage is observed, replace the worn valve using procedures found in EB-03516.
2. Improper actuation: This can be observed by viewing the stem of the valve poppet actuator. When the valve is actuated the stem should protrude slightly from the top of the valve. If the stem is recessed into the valve body without a
signal applied, the valve is not seated properly, or the actuator/poppet is defective. If the valve is not actuating properly, replace the failed valve using procedures found in EB-03516.
-491-

Figure 10-19 EO-5093-700-005, FITTING WRENCH
WARNING
WARNING
equipment.

EO-5093-700-005
[EO-5093-700-005] REV B2
FITTING WRENCH SHEET 1 OF 1
-492-
Figure 10-20 EO-5093-700-017, REGULATOR SEAT TOOL
WARNING
WARNING
equipment.
[EO-5093-700-017] REV 0
REGULATOR SEAT TOOL SHEET 1 OF 1
-493-
Figure 10-21 EO-9999-111-701, PARKER FITTING INSTALL ASSEMBLY 8MM
WARNING
WARNING
equipment.
EO-9999-111-760
EO-9999-111-750
EO-9999-111-751
NOTES:
1. Parker part number: TPA-8MM
[EO-9999-111-701] REV A
PARKER FITTING INSTALL ASSEMBLY 8MM SHEET 1 OF 1
-494-
Figure 10-22 EO-9999-111-702, PARKER FITTING UNINSTALL ASSEMBLY 8MM
WARNING
WARNING

EO-9999-111-750
EO-9999-111-752
NOTES:
1. Parker part number: TPR-8MM
[EO-9999-111-702] REV A
PARKER FITTING UNINSTALL ASSEMBLY 8MM
SHEET 1 OF 1
-495-
WARNING
WARNING
equipment.

EO-9999-111-750
EO-9999-111-753
NOTES:
[EO-9999-111-703] REV A
PARKER FITTING INSTALL ASSEMBLY SHEET 1 OF 1
12MM
-496-
WARNING
WARNING
equipment.

EO-9999-111-750
EO-9999-111-754
NOTES:
[EO-9999-111-704] REV A
SHEET 1 OF 1
-497-
Figure 10-25 EO-9999-111-705, PARKER FITTING INSTALL ASSEMBLY 250
WARNING
EO-9999-111-750 WARNING
equipment.

EO-9999-111-755
Notes:
[EO-9999-111-705] REV A
PARKER FITTING INSTALL ASSEMBLY 250 SHEET 1 OF 1
-498-
Figure 10-26 EO-9999-111-706, PARKER FITTING INSTALL ASSEMBLY 250SS
WARNING
WARNING
equipment.

EO-9999-111-760 SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-9999-111-756
Notes:
[EO-9999-111-706] REV A
250SS
-499-
-500-
11 Color Changer – IPC MARMCP7AP07071E REV. C
11 COLOR CHANGER – IPC

11.1 Overview
The color changer enables the robot to switch between colors without color contamination, and provides a cleaning function to clean the paint lines from the color changer through the applicator. The Color Changer consists of the
SolvAir module, at least one color module, and a pressure regulator.
-501-
MARMCP7AP07071E REV. C 11 Color Changer – IPC
Figure 11-1 EO-5093-510-001 Sheet 1 of 2, 1K COLOR STACK ARM ASSEMBLY

WARNING
1K COLOR STACK ASSEMBLY WITH RECIRCULATING COLOR SLICE procedures when you install or remove
p2T
EO-HOSE-011-004
LENGTH = "D"
WARNING
FITCO000001488O - 2T Always disconnect power to the robot
SEE NOTE 9 before you perform any service or
pCC EO9999-200-001E you could injure personnel or damage
EO-HOSE-011-004 equipment.
LENGTH = "D" FITCO000001331O (2)
SEE NOTE 9
EO-4696-522-000 (2) UNLESS OTHERWISE NOTED:
pAIR CHECK VALVE SEE EG-00008 FOR LOCTITE REQUIREMENTS
EO-HOSE-011-004 SEE NOTES 10, 11 & 12. pCOLOR - ODD SEE EG-00010 FOR TORQUE SPECIFICATIONS
LENGTH = "D" EO-HOSE-011-004
SEE NOTE 9 LENGTH = 200 MM
QTY 'A' IN TABLE
A 29X FITCO000001381O SEE NOTE 8
REF.
pCOLOR - EVEN
EO-HOSE-011-004
LENGTH = 300 MM
EO-5093-510-013 QTY 'B' IN TABLE
pSOL SEE NOTE 8
EO-HOSE-011-004
LENGTH = "E"
SEE NOTE 9 pREG
EO-5093-150-005 REF EO-HOSE-011-004
SEE NOTE 6 LENGTH = 300 MM
QTY'C' IN TABLE
SEE NOTE 9
NOTES: SSHCM006100050S (4)

MOUNTING SCREWS
1. 1K COLOR STACK ASM SHOWN WITH RECIRCULATING COLOR SLICES, SEE NOTE 7
24 COLORS AND AIR PILOT REGULATOR.
2. COLOR STACK ASM. AVAILABLE WITH 4, 8, 12, 16, 20 AND 24 COLORS. EO-5093-150-001
SEE TABLE FOR SPECIFIC CONFIGURATIONS. SEE NOTE 6
3. THREE REGULATORS AVAILABLE. SEE TABLE FOR SPECIFIC
CONFIGURATIONS.
5. COLOR PILOT LINE - EVEN: (2) PER COLOR SLICE
6. TAG KIT: EO-5093-150-004 INCLUDES REQUIRED TAGS
7. PLACE THESE SCREWS IN A PLASTIC BAG AND TYRAP TO COLOR
STACK ASSEMBLY FOR LATER USE.
8. CAP BUNDLES OF (4) PILOT LINES WITH HOSE CAP (CAPMO000000101O)
9. CAP 4mm LINES WITH HOSE CAP (CAPMO000000098O) FITEO000001526O
10. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK EO-4657-503-050
VALVE. DO NOT PUT TEFLON TAPE ON THE 1ST 3 LEADING THREADS EO-5093-150-002 REF
OF THE MALE NPT. SEE NOTE 6
12. DO NOT USE LARGE HEX TO TIGHTEN CHECK VALVE. SEE EG-00492. REGULATOR ASM.
13. FOLLOW INSTRUCTIONS IN EG-00421 FOR SERTO FITTING EO5093-503-000C SHOWN
SEE NOTES 1, 3
INSTALLATION.
DETAIL A
SCALE 1 : 4 EO4657-502-000G
COLOR SLICE ASM.
SEE NOTE 2

[EO-5093-510-001] REV *16

1K COLOR STACK ARM ASSEMBLY SHEET 1 OF 2
-502-
Figure 11-2 EO-5093-510-001 Sheet 2 of 2, 1K COLOR STACK ARM ASSEMBLY
WARNING
1K COLOR STACK ASSEMBLY WITH NON-RECIRCULATING COLOR SLICE p2T
EO-HOSE-011-004 FITCO000001488O
LENGTH = 'D'
SEE NOTE 9 EO9999-200-001E
pAIR
EO-HOSE-011-004 FITCO0000013310 (2)
WARNING
LENGTH = 'D' Always disconnect power to the robot
SEE NOTE 9 EO-4696-522-000 (2) before you perform any service or
CHECK VALVE maintenance procedures. Otherwise,
SEE NOTES 10, 11 & 12 you could injure personnel or damage
pCC equipment.
EO-HOSE-011-004 COLOR PILOT - ODD
LENGTH = 'D' EO-HOSE-011-004
SEE NOTE 9 UNLESS OTHERWISE NOTED:
LENGTH = 200 MM
QTY 'A' IN TABLE SEE EG-00008 FOR LOCTITE REQUIREMENTS
29X FITCO000001381O SEE NOTE 8 SEE EG-00010 FOR TORQUE SPECIFICATIONS
REF.
COLOR PILOT - EVEN
EO-HOSE-011-004
pSOL LENGTH = 300 MM
EO-HOSE-011-004 QTY 'B' IN TABLE
B LENGTH = 'E' SEE NOTE 8
SEE NOTE 9
pREG
EO-5093-150-005 REF EO-HOSE-004
LENGTH = 300 MM
EO-5093-510-013 QTY 'C' IN TABLE
SEE NOTE 9
SSHCM006100050S (4)
MOUNTING SCREWS
SEE NOTE 7
NOTES:
1. 1K COLOR STACK ASM SHOWN WITH NON-RECIRCULATING COLOR SLICES, 24

COLORS AND AIR PILOT REGULATOR.
2. COLOR STACK ASM. AVAILABLE WITH 4, 8, 12, 16, 20 AND 24 COLORS. SEE TABLE
FOR SPECIFIC CONFIGURATIONS. EO-5093-150-001 REF.
3. THREE REGULATORS AVAILABLE. SEE TABLE FOR SPECIFIC CONFIGURATIONS.
5. COLOR PILOT LINE - EVEN: (2) PER COLOR SLICE
6. TAG KIT: EO-5093-150-004 INCLUDES REQUIRED TAGS EO-5093-150-002 REF.
7. PLACE THESE SCREWS IN A PLASTIC BAG AND TYRAP TO COLOR STACK FITEO000001526O
ASSEMBLY FOR LATER USE. EO-4657-503-050
8. CAP BUNDLES OF (4) PILOT LINES WITH HOSE CAP (CAPMO000000101O)
9. CAP 4mm LINES WITH HOSE CAP (CAPMO000000098O)
10. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK VALVE. DO
NOT PUT TEFLON TAPE ON THE 1ST 3 LEADING THREADS OF THE MALE NPT. DETAIL B
11. USE TEFLON TAPE (TAPEO000000003O) ON 1/4 MALE NPT OF SERTO FITTING(s)
FOR CHECK VALVE. DO NOTE PUT TEFLON TAPE ON THE 1ST 3 THREADS OF THE SCALE 1 : 4 REGULATOR ASM
EO5093-503-000C SHOWN
MALE NPT.
12. DO NOT USE LARGE HEX TO TIGHTEN CHECK VALVE. SEE EG-00492. SEE NOTES 1,3
EO4657-505-000E
NON-RECIRC
COLOR SLICE ASM
SEE NOTE 2
[EO-5093-510-001] REV *16

1K COLOR STACK ARM ASSEMBLY SHEET 2 OF 2
-503-
Figure 11-3 EO-6102-510-001, P500iA COLOR STACK ARM ASSEMBLY
WARNING
COLOR STACK ASSEMBLY components. Otherwise you could

WARNING
equipment.
FITCO000001331O (2)
EO-4696-522-000 (2) SEE EG-00008 FOR LOCTITE REQUIREMENTS
CHECK VALVE SEE EG-00010 FOR TORQUE SPECIFICATIONS
SEE NOTES 4, 5 & 6
SSHCM006100055G (REF)
MOUNTING SCREW
EO4657-501-000A (1)
FITTO000000788O (1)
FITRO000000489O (1)
NOTES: FITCO0000001330O (1)
DETAIL A
1. 1K COLOR STACK ASM SHOWN WITH RECIRCULATING COLOR SLICES, 24 COLORS AND AIR PILOT
REGULATOR.
SCALE 1 : 4
2. COLOR STACK ASM. AVAILABLE WITH 4, 8, 12, 16, 20 AND 24 COLORS,
RECIRC AND NON-RECIRC VALVES. SEE TABLE FOR SPECIFIC CONFIGURATIONS.
3. VARIABLE, 15 PSI FIXED, 30 PSI FIXED REGULATORS AVAILABLE. SEE TABLE FOR SPECIFIC
CONFIGURATIONS.
4. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK VALVE. DO NOT PUT TEFLON
TAPE ON THE 1ST 3 LEADING THREADS OF THE MALE NPT.
5. FOLLOW THREAD SEALANT INSTRUCTIONS IN EG-0008 FOR FITTINGS. REGULATOR ASM.
6. DO NOT USE LARGE HEX TO TIGHTEN CHECK VALVE. SEE EG-00492. EO5093-503-000C SHOWN
7. FOLLOW INSTRUCTIONS IN EG-00421 FOR SERTO FITTING INSTALLATION. SEE NOTES 1, 3
FITEO000001526O
EO-4657-503-050
RECIRCULATING COLOR VALVE ASSEMBLIES NON-RECIRCULATING COLOR VALVE ASSEMBLIES

510 Assembly No. Description Regulator Regulator # of colors # of Color Slices Regulator # of Color Slices
Type Part No. (EO4657-502-000G) 510 Assembly No. Description Regulator Type # of colors
Part No. (EO4657-505-000E)
EO6102-510-001A 1K CC ASM: Rec,vReg,4 clr Air Pilot EO5093-503-000C 4 1 EO6102-510-001G 1K CC ASM: NRec,vReg,4 clr Air Pilot EO5093-503-000C 4 1
EO6102-510-001B 1K CC ASM: Rec,vReg,8 clr Air Pilot EO5093-503-000C 8 2 EO6102-510-001H 1K CC ASM: NRec,vReg,8 clr Air Pilot EO5093-503-000C 8 2
EO6102-510-001C 1K CC ASM: Rec,vReg,12 clr Air Pilot EO5093-503-000C 12 3 EO6102-510-001J 1K CC ASM: NRec,vReg,12 clr Air Pilot EO5093-503-000C 12 3
EO6102-510-001D 1K CC ASM: Rec,vReg,16 clr Air Pilot EO5093-503-000C 16 4 EO6102-510-001K 1K CC ASM: NRec,vReg,16 clr Air Pilot EO5093-503-000C 16 4
EO6102-510-001E 1K CC ASM: Rec,vReg,20 clr Air Pilot EO5093-503-000C 20 5 EO6102-510-001L 1K CC ASM: NRec,vReg,20 clr Air Pilot EO5093-503-000C 20 5
EO6102-510-001F 1K CC ASM: Rec,vReg,24 clr Air Pilot EO5093-503-000C 24 6 EO6102-510-001M 1K CC ASM: NRec,vReg,24 clr Air Pilot EO5093-503-000C 24 6
EO6102-510-001N 1K CC ASM: Rec,15psi Reg,4 clr 15 psi fixed EO5093-503-000A 4 1 EO6102-510-001U 1K CC ASM: NRec,15psi Reg,4 clr 15 psi fixed EO5093-503-000A 4 1
EO6102-510-001P 1K CC ASM: Rec,15psi Reg,8 clr 15 psi fixed EO5093-503-000A 8 2 EO6102-510-001V 1K CC ASM: NRec,15psi Reg,8 clr 15 psi fixed EO5093-503-000A 8 2
EO6102-510-001Q 1K CC ASM: Rec,15psi Reg,12 clr 15 psi fixed EO5093-503-000A 12 3 EO6102-510-001W 1K CC ASM: NRec,15psi Reg,12 clr 15 psi fixed EO5093-503-000A 12 3
EO6102-510-001R 1K CC ASM: Rec,15psi Reg,16 clr 15 psi fixed EO5093-503-000A 16 4 EO6102-510-001X 1K CC ASM: NRec,15psi Reg,16 clr 15 psi fixed EO5093-503-000A 16 4
EO6102-510-001S 1K CC ASM: Rec,15psi Reg,20 clr 15 psi fixed EO5093-503-000A 20 5 EO6102-510-001Y 1K CC ASM: NRec,15psi Reg,20 clr 15 psi fixed EO5093-503-000A 20 5
EO6102-510-001T 1K CC ASM: Rec,15psi Reg,24 clr 15 psi fixed EO5093-503-000A 24 6 EO6102-510-001Z 1K CC ASM: NRec,15psi Reg,24 clr 15 psi fixed EO5093-503-000A 24 6
EO6102-510-001AA 1K CC ASM: Rec,30psi Reg,4 clr 30 psi fixed EO5093-503-000B 4 1 EO6102-510-001AG 1K CC ASM: NRec,30psi Reg,4 clr 30 psi fixed EO5093-503-000B 4 1
EO6102-510-001AB 1K CC ASM: Rec,30psi Reg,8 clr 30 psi fixed EO5093-503-000B 8 2 EO6102-510-001AH 1K CC ASM: NRec,30psi Reg,8 clr 30 psi fixed EO5093-503-000B 8 2
EO6102-510-001AC 1K CC ASM: Rec,30psi Reg,12 clr 30 psi fixed EO5093-503-000B 12 3 EO6102-510-001AJ 1K CC ASM: NRec,30psi Reg,12 clr 30 psi fixed EO5093-503-000B 12 3
EO6102-510-001AD 1K CC ASM: Rec,30psi Reg,16 clr 30 psi fixed EO5093-503-000B 16 4 EO6102-510-001AK 1K CC ASM: NRec,30psi Reg,16 clr 30 psi fixed EO5093-503-000B 16 4
EO6102-510-001AE 1K CC ASM: Rec,30psi Reg,20 clr 30 psi fixed EO5093-503-000B 20 5 EO6102-510-001AL 1K CC ASM: NRec,30psi Reg,20 clr 30 psi fixed EO5093-503-000B 20 5
EO6102-510-001AF 1K CC ASM: Rec,30psi Reg,24 clr 30 psi fixed EO5093-503-000B 24 6 EO6102-510-001AM 1K CC ASM: NRec,30psi Reg,24 clr 30 psi fixed EO5093-503-000B 24 6
FANUC Part No. DESCRIPTION

[EO-6102-510-001] REV *6
P500iA COLOR STACK ARM ASSEMBLY SHEET 1 OF 1
-504-
Figure 11-4 EO-6263-510-001 Sheet 1 of 2, 1K COLOR STACK ASM
WARNING
WARNING
1K COLOR STACK ASM Always disconnect power to the robot
LEFT INNER ARM OFFSET SHOWN maintenance procedures. Otherwise,
(EO6263-510-001F SHOWN) you could injure personnel or damage
equipment.

COLOR LINES

NUTHM006100000S M6 X 1.0 Stainless Steel Hex Nut
WSHFM060012016S M6 Stainless Steel Flat Washer
[EO-6263-510-001] REV *4
1K COLOR STACK ASM SHEET 1 OF 2
-505-
Figure 11-5 EO-6263-510-001 Sheet 2 of 2, 1K COLOR STACK ASM
WARNING
REGULATOR ASM procedures when you install or remove
EO5093-503-000C SHOWN components. Otherwise you could
SEE NOTES 1,3 injure personnel or damage equipment
RE-CIRCULATING COLOR BLOCK
EO4657-502-000G EO4657-501-000A
SEE NOTE 2 SOLVAIR BLOCK WARNING
FITCO000001361O SEE DETAIL VIEW "B" Always disconnect power to the robot
SEE CHART FOR SOLVAIR you could injure personnel or damage
CONNECTIONS equipment.
SEE NOTE 8
4X SSHCM006100055S
4X NUTHM006100000S UNLESS OTHERWISE NOTED:
4X WSHFM060012016S SEE EG-00008 FOR LOCTITE REQUIREMENTS
SEE NOTE 3 SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-HOSE-011-004
L = 725mm
pREG
DETAIL A
SCALE 1 : 3 SOLVENT SUPPLY
3X TUBEM060000017O
L=30mm COLOR LINES REMOVED
FOR CLARITY AIR SUPPLY
3X FITEO000001664O
2X EO-4696-522-000
CHECK VALVE
SEE NOTES 5, 6, 7
TUBEM060000017O
L=45mm LH ROBOTS
L=30mm RH ROBOTS NOTES:
FITTO000000796O 1. 1K COLOR STACK ASM SHOWN WITH RECIRCULATING COLOR SLICES, 24 COLORS
AND AIR PILOT REGULATOR.
2. COLOR STACK ASM. AVAILABLE WITH 4, 8, 12, 16, 20 AND 24 COLORS. SEE TABLE FOR
SPECIFIC CONFIGURATIONS.
3. PLACE THESE SCREWS, NUTS, AND WASHERS IN A PLASTIC BAG AND TYRAP TO
2X FITCO000001331O COLOR STACK ASSEMBLY FOR LATER USE.
4. CAP 4mm LINES WITH HOSE CAP (CAPMO000000098O)
FITCO000001330O CAP 6mm LINES WITH HOSE CAP (CAPMO000000099O)
FITRO000000489O 5. USE TEFLON TAPE (TAPEO000000003O) ON 3/8 MALE NPT OF CHECK VALVE.
DO NOT PUT TEFLON TAPE ON THE 1ST 3 LEADING THREADS OF THE MALE NPT.
DETAIL B 7. DO NOT USE LARGE HEX TO TIGHTEN CHECK VALVE. SEE EG-00492.
8. SOLVAIR PILOT LINE LENGTHS VARY WITH NUMBER OF COLORS. THE MAXIMUM LEGTH
SCALE 1 : 2 IS SHOWN IN THE CHART.
[EO-6263-510-001] REV *4
1K COLOR STACK ASM SHEET 2 OF 2
-506-

Figure 11-6 EO-4657-501-000, SOLV/AIR 3 VALVE ASM
WARNING
WARNING
equipment.
3X FITMO000001982O
3X EO9999-200-001N
"A" SEE CHART
2X EO-4657-502-002
3X EO-5513-007-000
EO9999-200-003C
NOTES:
FANUC ASSEMBLY NO. DESCRIPTION "A" SIZE
2. FITTING COMES WITH COLLET, CARTRIDGE, AND O-RING. DO NOT USE THE CARTRIDGE AND O-RING. EO4657-501-000A 3/8 NPT SOLVAIR BLOCK 3/8 NPT
3. LUBRICATE O-RINGS WITH A THIN COAT OF DIELECTRIC GREASE (EO-4526-050-009) PRIOR TO INSTALLATION EO4657-501-000D 3/8 BSPT SOLVAIR BLOCK 3/8 BSPT
[EO-4657-501-000] REV *8
SOLV/AIR 3 VALVE ASM SHEET 1 OF 1
-507-
Figure 11-7 EO-5093-510-013, SOLV/AIR 4VALVE ASM
WARNING
WARNING
equipment.

4X FITMO000001982O
SEE NOTE 2
4X EO9999-200-001N
2X EO-4657-502-002
4X EO-5513-007-000
SEE NOTE 1
EO9999-200-003C
NOTES:

2. FITTING COMES WITH COLLET, CARTRIDGE, AND O-RING. DO NOT USE THE CARTRIDGE AND O-RING.
3. LUBRICATE O-RINGS WITH A THIN COAT OF DIELECTRIC GREASE (EO-4526-050-009) PRIOR TO INSTALLATION
[EO-5093-510-013] REV C1
SOLV/AIR 4VALVE ASM SHEET 1 OF 1
-508-
This module allows purge solvent and purge air to be simultaneously delivered to the Color Changer. This mechanical feature eliminates the need for added programming steps typically alternating the SOL valve and then an air valve
several times during a color change cleanout cycle. A secondary outlet, 2T is used for routing solvent, air, or aerated SolvAir mix to the applicator.
SolvAir solvent regulator flow rates:
SPECIFIC GRAVITY = 1.0 (water)

0.38 – 0.42 gpm = 24.0-26.5 cc/s
SPECIFIC GRAVITY = 0.9

0.40 – 0.44 gpm = 25.3-27.9 cc/s
SPECIFIC GRAVITY = 0.8 (Methyl Isobutyl Ketone)

0.42 – 0.47 gpm = 26.8-29.6 cc/s
The SolvAir module is located at the rear of the Color Changer. It consists of three or four paint valves (EO-5513-002-000) to control the air inlet, solvent inlet, and the 2T valve, along with the SolvAir endcap,
The SolvAir Module connects to the color module using 2 color manifold screws (EO-4657-502-002) using a 6mm allen wrench.
The SolvAir Module connects to the arm using 2 screws (SSHCM006100055G).
The paint valves screw into the SolvAir module using the Valve Tool as shown in the Special Tools Section. See EB-03516.
Caution: Do not remove Solv-Air flow control module.
The pilot lines for the AIR, SOL, CC, and 2T valves plug into fittings, FITMO000001982O.
Two check valves (EO4696-522-000) are attached to the air inlet and solvent inlet ports.
Caution: It is crucial to the operation of the SolvAir valve that the solvent inlet pressure is at least 10 PSI higher than the air inlet Pressure or the unit will not work properly and result in color carry-over or high voltage faults.
The pilot lines for the AIR, SOL, CC, 2T, SOL2, and DUMP3 valves plug into 5 fittings, FITMO000001982O.
Check valves (EO4696-522-000) are attached to the air inlet and solvent inlet ports.
Caution: It is crucial to the operation of the SolvAir valve that the solvent inlet pressure is at least 10 PSI higher than the air inlet Pressure or the unit will not work properly and result color carry-over or high voltage faults.
-509-
11.2.2 Color Module – Recirculating

Figure 11-8 EO-4657-502-000, COLOR MODULE
WARNING
(2) SCREW
EO-4657-502-002
KATES NO. FR21-2 WARNING
(4) "B" O-RING (OUTLET)
MICROVALVE EO9999-200-003C maintenance procedures. Otherwise,
SEE TABLE KATES NO. SP7536 you could injure personnel or damage
equipment.
56.0
EO-4657-502-002G
"A"
NYLON TUBE FITTING
(SEE TABLE)
(4) PUSH-TO-LOCK TUBE FIT'G (4-mm)
FITMO000001982O
KATES NO. FSA12-151
(4) O-RING
EO9999-200-001N
KATES NO. FSA12-161
EO-4657-502-002C
[EO-4657-502-000] REV *14

COLOR MODULE SHEET 1 OF 1
-510-
The circulating Color Module (EO-4657-502-000) is the point where the paint enters the IPC color system. It consists of 4 air piloted paint valves. Each color valve has a supply and return paint circulation line, connected by a fitting
(FITCO000001365O). Install the plastic hex fittings flush to block face.
The color block connects to the adjacent block using 2 screws (EO-4657-502-002) with a 6mm Allen wrench. The fluid passage connects to the adjacent block with an outlet surrounded by a face seal o-ring (EO9999-200-003C)
Depending on the number of colors being used, the following block could be another recirculating Color Module, or a pressure regulator if no more colors are being used.
The non circulating Color Module (EO-4657-504-000) is the point where the paint enters the IPC color system. It consists of 4 air piloted paint valves. Each color valve has a supply paint circulation line, connected by a plastic fitting
(FITCO000001329O). Install the hex fittings flush to block face.
The color block connects to the adjacent block using 2 screws (EO-4657-502-002) with a 6mm allen wrench. The fluid passage connects to the adjacent block with an outlet surrounded by a face seal o-ring (EO9999-200-003C)
Depending on the number of colors being used, the following block could be another non circulating Color Module, or a pressure regulator if no more colors are being used.
-511-
11.2.3 Non-Recirculating Color Module

Figure 11-9 EO-4657-504-000, NON-RECIRCULATING COLOR SLICE
WARNING
4X SEE TABLE WARNING

equipment.

4X FITMO000001982O
4X EO9999-200-001N
2X EO-4657-502-002
4X EO-5513-001-000
FANUC PART NO. DESCRIPTION FITTING PART NO.

EO4657-504-000A NO TUBE FITTINGS -
EO4657-504-000B [3/8"] TUBE FITTINGS (QTY: 4) KATES SP7535 & SP7645
EO4657-504-000C 10/7-mm TUBE FITTINGS (QTY: 4) KATES SP7539
[EO-4657-504-000] REV *7
NON-RECIRCULATING COLOR SLICE SHEET 1 OF 1
-512-
11.2.4 Pressure Regulator

The air piloted pressure regulator (EO5093-503-000C) is connected to the last Color Module. This module controls the pressure of the paint supplied to the gear pump. A pilot air signal is applied to an internal diaphragm which in turn
controls a poppet valve within the regulator body.
11.2.5 Pressure Regulator (Fixed)

The fixed pressure regulator (EO5093-503-000B) is connected to the last Color Module. This module controls the pressure of the paint supplied to the gear pump. A constant force supplied by a spring is applied to an internal diaphragm
which in turn controls a poppet valve within the regulator body.
-513-
Figure 11-10 EO-5093-503-000, REGULATOR ASM
WARNING
EO5093-503-000B SHOWN components. Otherwise you could
NOTES:
1. THIS COMPONENT IS USED FOR PAINT DELIVERY. ALL INTERNAL WARNING

PASSAGES MUST BE FREE OF DIRT, CUTTING FLUID, CHIPS, ETC. Always disconnect power to the robot
AND DRY BEFORE PACKAGING. ALL INTERNAL PASSAGES before you perform any service or
SHOULD BE PROTECTED (EITHER PLUGGED OR COVERED) maintenance procedures. Otherwise,
DURING SHIPPING. NO SILICONES ARE TO BE USED FOR THE equipment.
MANUFACTURING OF THIS PART AND MATERIAL SHOULD BE
SILICONE FREE.
2. N/A UNLESS OTHERWISE NOTED:
3. N/A SEE EG-00008 FOR LOCTITE REQUIREMENTS
4. N/A SEE EG-00010 FOR TORQUE SPECIFICATIONS
5. N/A.
6. ASSEMBLE THESE PARTS AS PER EG-00420
7. N/A
8. N/A
EO9999-200-001M
FOR REBUILDING THE REGULATOR USE THE FOLLOWING KITS: EO-5093-503-000
Regulator Kit Part No Description Regulator type

EO5093-503-020A Complete Rebuild Kit 15 PSI Fixed
EO5093-503-020B Complete Rebuild Kit 30 PSI Fixed
EO5093-503-020C Complete Rebuild Kit Air Pilot EO5093-503-020D
EO5093-503-020D Soft Rebuild Kit N/A
ITEM B
ITEM A
FITMO000001982O (PUSH TO LOCK FITTING FOR VARIABLE REG)

QTY 'D'
SEE NOTE
EO9999-200-001N (O-RING FOR VARIABLE REG)
QTY 'D'
FANUC PART NO DESCRIPTION ITEM 'A' ITEM 'B' LABEL 'C' QTY 'D'
EO5093-503-000A 15 PSI FIXED REGULATION EO-5093-503-002 EO-5093-503-009 15 0
EO5093-503-000B 30 PSI FIXED REGULATION EO-5093-503-002 EO-5093-503-012 30 0
EO5093-503-000C VARIABLE REGULATION EO-5093-503-013 <NONE> <NONE> 1
[EO-5093-503-000] REV *7
REGULATOR ASM SHEET 1 OF 1
-514-
11.2.6 Maintenance and Repair

Figure 11-11 ET-5093-890-006 Sheet 1 of 2, P-700 1K Process Schedules
W A R N IN G
S om e com p o n e nts are h e avy. U se
EO -9 9 9 9-1 1 1-1 13
1 0 X 7 P AR K ER F IT TIN G S P 70 0 1 K P R O C E S S P M S C H E D U L E S P U M P B LO C K
pro ce d ure s w h e n yo u in sta ll or re m ove
P A IN T V A LV E S
EO -9 9 9 9-1 1 1-1 05
1 0 X 7 P AR K ER F IT TIN G S W A R N IN G
1K - 24 C O LO R S TA C K A lw a ys d isco n n ect p ow e r to th e ro b ot
b efo re yo u p erfo rm a ny se rvice or
P A R K E R F IT T IN G S m a inte n a nce pro ce d ure s. O th erw ise ,
yo u co u ld in ju re p erso n n e l or d am a g e
S C A L E 1 :2 .5 e q u ipm e nt.
U NLE S S O TH E R W IS E N O TE D :
S E E E G -0 0 0 0 8 F O R LO C T ITE R E Q U IR EM EN TS
E O -9 9 9 9-1 1 1-1 11 S E E E G -0 0 0 1 0 F O R TO R Q U E S P EC IF IC AT IO N S
6 X 4 P A R K E R F IT TIN G
F IT C O 0 0 0 0 0 1 3 3 1O E O -9 9 9 9-1 1 5-0 01
1 0 X 7 S E R T O F IT TIN G S 6 M M P A R K E R R IG H T A N G LE A D A P T E R
E O -4 6 9 6-5 2 2-0 0 0
C H E C K V A LV E S 1K PU M P BLO CK
F IT C O 0 0 0 0 0 1 4 8 8O S C A L E 1 :2
S E R T O F IT TIN G F IT E O 0 0 0 0 0 1 5 3 5O
F IT C O 0 0 0 0 0 1 3 2 9O S E R T O F IT T IN G
1 0 X 7 S E R T O F IT TIN G S
F IT T O 0 0 0 0 0 0 7 8 8O
S E R T O F IT TIN G
JO H N G U E S S
C O L LE T S E O 5 0 9 3-5 0 3-0 0 0C F IT C O 0 0 0 0 0 1 3 3 1O
A IR P IL O T R E G U L A T O R 1 0 X 7 S E R T O F IT T IN G S
S O LV -A IR B LO C K
P A IN T V A LV E S
C O L O R S L IC E
P A IN T V A L V E S F IT C O 0 0 0 0 0 1 3 3 2O
S E R T O F IT T IN G S
1K - 24 C O LO R S TA C K
S E R T O F IT T IN G S F IT E O 0 0 0 0 0 1 5 2 6O
S E R T O F IT T IN G 1K PU M P BLO C K Q D
S C A L E 1 :2 .5 S C A L E 1 :2
NO TES
1. U N L E S S O T H E R W IS E N O T E D , A L L F A S T E N E R S M U S T B E T IG H T E N E D A S
P E R T O R Q U E S P E C IF IC A T IO N S IN E G 0 0 0 1 0.
2. F O L LO W S E R T O R E C O M M E N D E D IN S T A L LA T IO N P R O C E D U R E F O R P A
F IT TIN G S T O IN S T A L L A L L S E R T O F IT TIN G S .
3. A L L F IT T IN G S M U S T B E R E P LA C E D A S N E E D E D U P O N R E G U LA R
IN S P E C T IO N .
4. P L E A S E R E F E R T O S H E E T 2 F O R S P E C IA L M A IN T E N A N C E S C H E D U L E S .
A P P LIC A T O R
P A IN T V A LV E S
V B II 6 0 D E G A P P L IC A T O R
S C A L E 1 :5
[E T -5 0 9 3-8 9 0-0 0 6] REV A
P -7 0 0 1K Process S ch e d ules SHEET 1 OF 2
-515-
Figure 11-12 ET-5093-890-006 Sheet 2 of 2, P-700 1K Process Schedules
W A R N IN G
S o m e co m p o n e nts a re h e avy. U se
extre m e ca re a n d fo llo w pro p er liftin g
proce d ure s w h e n yo u in sta ll or rem ove
P A IN T V A LV E S - G E N E R A L M A IN T E N A N C E G U ID L IN E S in ju re p erso n n e l o r d am a g e e q u ipm e nt
1. IN S P E C T A L L P A IN T V A LV E S D U R IN G W E E K LY M A IN T E N A N C E F O R LE A K S A N D /O R M A L F U N C T IO N .
2. P A IN T V A L V E IS N O T F IE L D S E R V IC E A B L E U N IT .
3. P A IN T V A L V E M U S T B E R E P L A C E D A S A W H O L E . W A R N IN G
4. R E P LA C E A D A M A G E D V A L E V E W IT H A N E W V A L V E . A lw a ys d isco n n ect p ow er to th e ro b ot
5. D IS C A R D D A M A G E D P A IN T V A LV E S P R O M P T LY - D O N O T S T O R E T H E M . b efo re yo u p erform a ny se rvice o r
6. L IF E O F A P A IN T V A L V E U N D E R N O R M A L O P E R A T IO N IS 2 ,0 0 0,0 0 0 (T W O M IL LIO N ) C Y C LE S . m a inte n a nce p ro ce d ures. O th erw ise ,
7. R E P LA C E P A IN T V A L V E S A C C O R D IN G T O T H E F O L LO W IN G S C H E D U LE : yo u co u ld in ju re p erso n n e l or d am a g e
e q u ipm e nt.
U N LE S S O TH ER W IS E N O TED :
S E E EG -0 0 0 0 8 FO R LO C TIT E R EQ U IR EM EN TS
R E P LA C E NO. OF Y E A RS NO . OF Y E A RS S E E EG -0 0 0 1 0 FO R TO R Q U E S P EC IF IC ATIO N S
P A IN T V A LV E A V G C Y C LE S A F TE R H O U R S W ITH O N E 10H R W ITH TW O 10 H R
LO C A TIO N P E R JO B IN U S E S H IF T S H IF TS
C O LO R S TA C K 1 30,000 10 Y R S 2 Q TR S 5 Y R S 1 Q TR
S O LV -A IR B LO C K 2 15,000 5 Y R S 1 Q TR 2 Y R S 2 Q TR S
P U M P B LO C K 2 15,000 5 Y R S 1 Q TR 2 Y R S 2 Q TR S
A P P LIC A TO R 3 10,000 3 Y R S 2 Q TR S 1 Y R 3 Q TR
H O S E S - G E N E R A L M A IN T E N A N C E G U ID L IN E S
1. IN S P E C T A L L H O S E S D U R IN G W E E K LY M A IN T E N A C E .
2. M A K E S U R E T H A T T H E R E IS N O F LU ID O F A N Y K IN D IN A IR P ILO T H O S E S .
3. R E P LA C E D A M A G E D O R F A U L T Y H O S E S A S N E E D E D .
4. R E P LA C E H O S E A L O N G W IT H F IT T IN G S A T B O T H E N D S .
5. R E P LA C E H O S E S A C C O R D IN G T O T H E F O L LO W IN G S C H E D U L E :
P A IN T S U P P L Y H O S E S - F R O M P A IN T D R O P T O C O LO R S T A C K - A N N U A L
S O L V E N T A N D A IR S U P P L Y H O S E S - A N N U A L
P IL O T H O S E S O N IN N E R A R M - A N N U A L
W A S H L IN E - F R O M S O LV A IR B LO C K T O P U M P B LO C K - A N N U A L
P A IN T -IN LIN E - F R O M R E G U LA T O R T O P U M P B L O C K - A N N U A L
H O S E B U N D L E - E O -5 0 9 3-5 4 5-0 0 0 A S S E M B L Y - 6 M O N T H S
S E R T O F IT TIN G S A N D JO H N G U E S S C O L LE T S
1. IN S P E C T A L L F IT TIN G S D U R IN G W E E K L Y M A IN T E N A N C E .
2. A L L F IT T IN G S M U S T B E R E P L A C E D A S N E E D E D U P O N R E G U L A R IN S P E C T IO N .
3. D IS C A R D T H E R E P LA C E D F IT T IN G S - D O N O T S T O R E T H E M .
O T H E R P A R T S M A IN T E N A N C E S C H E D U LE
3. 3 C C G E A R P U M P - R E F E R T O G E A R P U M P M A IN T E N A N C E (ET -5 0 9 3-8 9 0-0 0 7)
[ET-5 0 9 3-8 9 0-0 0 6] REV A

P -7 0 0 1K Process S ch e d ules SHEET 2 O F 2
-516-
Figure 11-13 ET-5093-890-005 Sheet 1 of 3, 5093 REGULATOR
WARNING
5093 REGULATOR components. Otherwise you could

WARNING
equipment.

ITEM A ITEM A
REFER TABLE REFER TABLE
EO-5093-503-000C SHOWN EO-5093-503-000C SHOWN
3 X 6 FEP TUBING TO
PUMP BLOCK PAINT INLET
1/4 NPT SERTO ELBOW TEFLON BUTTON INSERT

FITEO000001526O EO-4657-503-050 1/4 NPT SERTO ELBOW
1/4 NPT FEMALE THD FITEO000001526O
1/4 NPT MALE THD

APPLY DIELECTRIC GREASE
[ET-5093-890-005 ] REV B7
5093 REGULATOR SHEET 1 OF 3
-517-
WARNING
TIGHTEN CAP TO
ITEM B
REGULATOR CAP
5 Nm [45 in-lbs] EO-5093-503-018 WARNING
NUT Always disconnect power to the robot
TIGHTEN POPPET ASSY before you perform any service or
47.63 [ 1.875] MALE THREAD TO 2 Nm [15 in-lbs] maintenance procedures. Otherwise,
(1 7/8 - 16 UN - 2A) EO9999-200-004L you could injure personnel or damage
APPLY DIELECTRIC GREASE 2-028 O-RING equipment.

SPACER RING SEE EG-00008 FOR LOCTITE REQUIREMENTS
ITEM A
LOAD SPRING SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-5093-503-005
WASHER
REGULATOR DIAPHRAGM EO-5093-503-019
SUB-ASSEMBLY BACKUP DIAPHRAGM
B EO-5093-503-014
DIAPHRAGM
EO9999-200-001D (O-RING)
REGULATOR SEAT
SUB-ASSEMBLY
A EO-5093-503-015
POPPET
DETAIL B
EO9999-200-001T SCALE 1 : 1
2-028 O-RING
EO-5093-503-001
REGULATOR BLOCK
EO9999-200-001AA
2-017 O-RING
EO-5093-503-004
REGULATOR SEAT
EO9999-200-001H
2-014 O-RING
REGULATOR ASSEMBLY
INTERNAL PARTS EO-5093-503-011
BALL
EO-5093-503-010
SPRING
DETAIL A
SCALE 1 : 1
[ET-5093-890-005 ] REV B7
-518-
WARNING
REGULATOR MAINTENANCE AND REPAIR WARNING

equipment.
REGULATOR MAINTENANCE SCHEDULE: UNLESS OTHERWISE NOTED:

1. INSPECT REGULATORS DURING WEEKLY MAINTENANCE FOR LEAKS AND/OR SEE EG-00008 FOR LOCTITE REQUIREMENTS
MALFUNCTION. SEE EG-00010 FOR TORQUE SPECIFICATIONS
2. MOST REGULATOR MALFUNCTIONS CAN BE REPAIRED IN FIELD BY REPLACING THE
DIAPHRAGM - USE REGULATOR SOFT REBUILD KIT EO5093-503-020D.
3. REBUILD THE REGULATOR INTERNAL PARTS EVERY 5,000 HOURS OF USE. USE
APPROPRIATE REBUILD KITS, EO5093-503-020A THRU C.
4. REPLACE SERTO ELBOW (FITEO000001526O) WHEN THE REGULATOR IS REBUILT.
MAINTENANCE PROCEDURES:
1. PERFORM A SUPER PURGE CYCLE BEFORE ANY REGULATOR MAINTENANCE.
2. DETACH THE REGULATOR FIRST FROM THE ROBOT ARM AND THEN FROM THE COLOR
STACK.
3. PLACE THE REGULATOR WITH CAP POINTING UP ON A CLEAN HORIZONTAL SURFACE.
4. USE ONLY VALVE INSTALL TOOL (EO-5513-700-003) TO REMOVE AND INSTALL THE CAP.
5. USE REGULATOR REBUILD KIT (EO5093-503-020D) TO REPLACE DIAPHRAGM.
6. PLACE THE DIAPHRAGM-POPPET ASSEMBLY INTO THE REGULATOR WHILE THE
REGULATOR IS IN UPRIGHT POSITION ONLY, TO PREVENT MISLAIGNMENT OF THE
POPPET.
7. IF ALL THE INTERNAL PARTS OF THE REGULATOR ARE TO BE REPLACED, REMOVE THE
REGULATOR TO A TABLE.
8. USE ONLY THE APPROPRIATE REBUILD KIT AS PER THE TABLE FOR REPLACING
INTERNAL PARTS.
[ET-5093-890-005 ] REV B7
-519-
1. Inspect all paint valves during weekly maintenance for leaks and/or malfunction, using procedures found in EB-03516.
2. The paint valve is not a field serviceable unit.
3. Paint valves must be replaced as a whole.
4. Replaced a damaged valve with a new valve.
5. Discard damaged paint valves promptly – do not store them.
6. Life of a paint valve under normal operation is 2,000,000 cycles.
7. Replace paint valves according to the following schedule from ET-5093-890-006 using procedures found in EB-03516.
Replace
Paint Valve Avg Cycles after hours No.of years with No. of years with
Location per Job in use. 1 hour shift 2 hour shift
Color Stack 1 30000 10 YRS 2 QTRS 5 YRS 1 QTR

Solv-Air Block 2 15000 5 YRS 1 QTR 2 YRS 2 QTR
Pump Block 2 15000 5 YRS 1 QTR 2 YRS 2 QTR
Applicator 3 10000 3 YRS 2 QTRS 1 YR 3 QTR
Table 11-1: Wear part replacement schedule

1. Replace valves in the SolvAir Module after 15,000 hours in use.
2. Replace check valves annually, as suggested in ET-5093-890-006.
11.2.8 Color Module

1. Inspect color module and valves during weekly maintenance.
2. Replace valves in color module after 30,000 hours in use.
Troubleshooting Paint Valves
1. Turn off all paint and solvent supplies to the color changer manifold. Relieve all potentially entrapped paint, solvent, or air pressure in the system undergoing maintenance.
2. Inspect valves for fresh fluid in the weep holes.
3. Disconnect pilot lines.
4. Remove the paint valve in question. Use the color valve tool EO-5513-700-003 or a 17mm wrench and grasp the hex head surfaces of the valve.
5. It may be necessary to remove paint lines in order to clean valve socket.
6. Clean the interior of the valve socket with solvent. Inspect the stainless steel valve seat for any damage.
-520-
7. Thoroughly clean valve socket and pilot passage before installing valve.
8. Discard the damaged valve and replace with a new one. Insure that the new valve is seated properly by observing the stem of the actuator. It should be flush with the top of the valve. If the valve is over tightened the stem will be
protruding from the top of the valve. If the stem is recessed into the valve, the valve is not tightened sufficiently.
If no SolvAir is produced when requested, such as when cleaning the shape air nozzles or cleaning lines during a color change, check the following items:
1. Verify that the SOL, AIR, and 2T valves actuate by observing the valve poppets. When the valve is actuated the stem should protrude slightly from the top of the valve. If the stem is recessed into the valve body without a signal
applied, the valve is not seated properly, or the actuator/poppet is defective. If the valve is not actuating properly, replace the failed valve using procedures found in EB-03516.
2. Verify that the solvent pressure is at least 10 PSI above supply air pressure.
11.3.2 Color Module

Typically only two problems arise with this color valve:
1. Leakage out the weep port or through a worn valve that is not seating properly. If leakage is observed, replace the worn valve using procedures found in EB-03516.
2. Improper actuation: This can be observed by viewing the stem of the valve poppet actuator. When the valve is actuated the stem should protrude slightly from the top of the valve. If the stem is recessed into the valve body without a
signal applied, the valve is not seated properly, or the actuator/poppet is defective. If the valve is not actuating properly, replace the failed valve using procedures found in EB-03516.
-521-
11.4 Spare parts and special tools

Figure 11-16 EO-9999-111-105, PARKER 7x10MM 3/8NPT FITTING ASSY
WARNING
WARNING
equipment.

EO-9999-111-006
EO-=9999-111-005
[EO-9999-111-105] REV A
PARKER 7x10MM 3/8NPT FITTING ASSY SHEET 1 OF 1
-522-
Figure 11-17 EO-5513-700-003, VALVE TOOL
WARNING
WARNING
equipment.

EO-58513-700-003
[EO-5513-700-003] REV C
VALVE TOOL SHEET 1 OF 1
Figure 11-18 EO-5093-700-005, FITTING WRENCH
-523-
WARNING
WARNING
equipment.

EO-5093-700-005
[EO-5093-700-005] REV B2
FITTING WRENCH SHEET 1 OF 1
-524-
Figure 11-19 EO-5093-700-017, REGULATOR SEAT TOOL
WARNING
WARNING
equipment.
[EO-5093-700-017] REV 0
REGULATOR SEAT TOOL SHEET 1 OF 1
-525-
WARNING
WARNING
equipment.
EO-9999-111-760
EO-9999-111-750
EO-9999-111-751
NOTES:
[EO-9999-111-701] REV A
PARKER FITTING INSTALL ASSEMBLY 8MM SHEET 1 OF 1
-526-
WARNING
WARNING

EO-9999-111-750
EO-9999-111-752
NOTES:
[EO-9999-111-702] REV A
SHEET 1 OF 1
-527-
WARNING
WARNING
equipment.

EO-9999-111-750
EO-9999-111-753
NOTES:
[EO-9999-111-703] REV A
12MM
-528-
WARNING
WARNING
equipment.

EO-9999-111-750
EO-9999-111-754
NOTES:
[EO-9999-111-704] REV A
SHEET 1 OF 1
-529-
Figure 11-24 EO-9999-111-705, PARKER FITTING INSTALL ASSEMBLY 250
WARNING
EO-9999-111-750 WARNING
equipment.

EO-9999-111-755
Notes:
[EO-9999-111-705] REV A
PARKER FITTING INSTALL ASSEMBLY 250 SHEET 1 OF 1
-530-
Figure 11-25 EO-9999-111-706, PARKER FITTING INSTALL ASSEMBLY 250SS
WARNING
WARNING
equipment.

EO-9999-111-760 SEE EG-00010 FOR TORQUE SPECIFICATIONS
EO-9999-111-756
Notes:
[EO-9999-111-706] REV A
250SS
-531-

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CONSIDERING SAFETY FOR YOUR ROBOT INSTALLATION

Keeping People Safe

Using Safety Enhancing Devices

Setting Up a Safe Workcell

Staying Safe While Teaching or Manually Operating the Robot

Staying Safe During Automatic Operation

Staying Safe During Inspection

When inspecting the robot, be sure to

Staying Safe During Maintenance

KEEPING MACHINE TOOLS AND EXTERNAL DEVICES SAFE

Programming Safety Precautions

Mechanical Safety Precautions

KEEPING THE ROBOT SAFE

Operating Safety Precautions

Programming Safety Precautions

ADDITIONAL SAFETY CONSIDERATIONS FOR PAINT ROBOT INSTALLATIONS

Paint robots are operated in three modes:

Paint System Safety Features

The paint system includes the following safety features:

Staying Safe While Operating the Paint Robot

 Know the work area of the entire paint station (workcell).

Special Precautions for Combustible Dusts (Powder Paint)

Staying Safe While Operating Paint Application Equipment

Staying Safe During Maintenance