PPH 707 SB Applicator Training Course

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PPH 707 SB Applicator

Training Course
This document is Sames Terchnologies property. Copy, photography or communication to somebody without written autorization is forbidden
Intitulé du document - Ind A - 9/16/2012 Not contactual document. Didactic document .Values and characteristics for example only. Doesn’t replace Sames user manuals
www.sames.com An EXEL Industries company

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Course Description
This course provides the detailed instruction and procedures

necessary for repairing and maintaining the Sames PPH 707
SB rotary atomizer.
During the course you will learn the main components of the
PPH 707 SB atomizer, disassemble the atomizer, reassemble
the atomizer and perform the preventative maintenance
procedures.
2 This document is Sames Terchnologies property. Copy, photography or communication to somebody without written autorization is forbidden
Not contactual document. Didactic document .Values and characteristics for example only. Doesn’t replace Sames user manuals

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Course Goals
1. Know what the PPH 707 is used for.

2. Know how the theory of operation for the PPH 707 SB.
3. Identify the main components of the PPH707 SB atomizer.
4. Know the correct air pressure and air volume to properly
operate the PPH 707 SB atomizer.
5. Know how to correctly disassemble and reassemble the
PPH 707 SB atomizer.
6. Know the preventative maintenance schedule for the PPH
707 SB atomizer.

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Course Outline/Table of Contents
1. Applicator Overview
2. Applications Where Used
3. Component Description
4. Technical Characteristics
5. Applicator Safety
6. Operation
7. Tools for Maintenance
8. Disassembly and Reassembly
9. Maintenance and Cleaning
10. Applicator Testing

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Pre-Test
Please answer all questions you know the answers to and

leave the ones you do not know the answer for blank.
The purpose of the pretest is to get a baseline of the class’

knowledge of the PPH707 prior to taking the course.

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The PPH 707 SB is the next generation solvent based paint

rotary paint atomizer from SAMES.
New Features:
Working components of the bell are within an easy to access assembly,
allowing for fast exchange.
Two paint circuits comes standard.
New robustly designed electrostatic cascade.
New shaping air technology providing transfer efficiency and appearance
improvements.
Faster robot velocity while applying paint.
New air and fluid fitting design which is sealed radially and axially.

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The PPH 707 SB is designed for use with solvent based paints
which have a high to medium resistivity (minimum of 3
MΩ.cm).
Typical Applications:
Automotive Exteriors
Automotive Interiors
Heavy Truck Exteriors
Heavy Truck Interiors
Metal Doors
Aerospace components
Military Vehicles and components
Plastic components.

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The PPH 707 is comprised of two assemblies.

1. The elbow assembly
2. The body assembly

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Elbow Assembly
1. Bell Cup
2. Shaping Air Assembly
3. Turbine
4. Injector and Injector Holder
5. Microvalve
6. Nanovalve
7. Elbow

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Le bol
Le bol pulvérise la peinture. Il est sélectionné selon le
type de produit utilisé et le type d’application.
35 mm Bol EC
50 mm Bol EC
65 mm Bol EC
65mm Bol EX
80mm Bol EX

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Shaping Air Assembly

The shaping air assembly controls the pattern diameter and
helps transfers the particles to the parts to be painted.
Hi-TE shaping air system utilizes both vortex and straight
configurations within a single ring around the bell cup.

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Turbine
The rotation of the bell cup is produced by a
pneumatic motor. Atomization results from the
centrifugal forces generated by rotation of the bell
cup.
Injector and Injector Holder

The injector transfers paint to the bell cup. The
holder retains the injector and allows it to be rinsed.

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Microvalve
Air-controlled, 2-way, normally closed valves used for: paint supply.
Nanovalve
Air-controlled, 2-way, normally closed valves used for: paint dump, bell
cup exterior rinsing and injector rinsing

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Elbow
The elbow houses all fluid, air/solvent microvalves, and air/solvent
nanovalves.
It supports the turbine and the shaping air shroud assembly
It is connected to the high-voltage unit and is used to charge the paint
particles.

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Body Assembly
1. Small Split Ring
2. Large Split Ring
3. Cover Nut
4. Quick Disconnect Plate
5. UHT 157 Cascade
6. Coil
7. Rear Support
8. Coil Block
9. Nut
10. Low Voltage Connection
11. Robot Adapter

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Small Split Ring

The small split ring is used to hold the elbow to
the body by holding the cover nut to the body
assembly, and is located at the front of the body
assembly and under the cover nut.
Large Split Ring

The large split ring is used to extract the elbow
during disassembly. The split ring is located at
the back of the body assembly.

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Cover Nut
The Cover Nut protects the internal
components against contamination and
damage by paint, plus also allows for easy
cleaning.
Quick Disconnect Plate

Provides a sealed interface for intake of
fluids and air. Allows for quick installation
and removal of the atomizer during
production.

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UHT 157 Cascade

Receives a low voltage supply that it converts into
high voltage for charging the atomized paint
particles.
Low Voltage Connection

The low voltage connection provides a stable
connecting point for the two low voltage cables to
be connected to the UHT 157 cascade.

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Coil
The coils extend the paint circuit and
maintain the voltage potential inside the
bell cup when spraying conductive
paints.
Coil Block
Grounds the coils to the robot wrist.
Prevents high voltage surges
potentially causing hose punctures.

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Rear Support
The rear support provides the structure for all of the body assembly
components to be attached to.

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Nut
Retains the rear part on the robot wrist.
Robot Adapter
Used to secure the atomizer to the robot
wrist and establish the connection to
ground.

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Weight
Atomizer weight without cables, cascade, or hoses
7 Kg
High-voltage unit UHT 157 Cascade
0,9 Kg
Air Quality
Dust : < 1 mg / m03
Oil: < 0,01 mg / m03
Particle diameter
Bearing air 0,1 µm
Turbine rotation 1 µm
Other 5 µm

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Dew Point
Dew point (pressurized air): < -40 °C
Air Pressure
Nanovalve pilot
8 bar (min.) - 10 bar (max.)
Microvalve pilot
6 bar (min.) - 10 bar (max.)
Bearing air
5,5 bar (min.) - 7 bar (max. at 130 l/min)
Shaping air
6 bar maximum
Microphone air
0,5 to 1 bar constant

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Air Consumption
Pilot
10 Nl/min
Bearing air
130 to 180 Nl/min
Shaping air 1
100 to 600 Nl/min
Shaping air 2
100 to 600 Nl/min
Turbine
100 to 700 Nl/min

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• Paint
– Normal supply pressure
• 6 to 10 bar
– Maximum pressure
• 10 bar
– Viscosity
• 20 to 40 seconds - FORD cup number 4
– Flow rate
• 30 to 1000 cm3/min (depending on paint)
– Paint resistivity
• > 3 MΩ.cm

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Bell Speed
Recommended rotation speed
15 to 85 Krpm (depend of bell size)
Robot Path Velocity

1500 mm/s
Voltage
Maximum operating voltage
100 kV
Maximum operating current
200 µA

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Dimensions and TCP Values
• X = -31,34 mm
• Y = 0,88 mm
• Z = 245,89 mm

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Bell Cup Safety

Always verify the bell is not spinning prior to attempting any work on
the PPH 707.
Use a rag bunched up in your hand to make first contact with the bell.
Avoid placing the bell cup onto hard surfaces with the cup edge and/or
serration making contact with the surface.
High Speed Turbine
Be careful to avoid moving the front of the turbine near iron based
metals as the front of the bearing contains a magnet.

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Nanovalve and Microvalve safety

Never remove a nanovalve or a microvalve when the fluid lines are
under pressure
Microphone safety
Make sure the robot is locked out before attempting to perform work
on the microphone.
Fiber Optic Safety
Make sure the robot is locket out before attempting to perform work on
the fiber optic system.

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Painting Safety
Make sure the part to be painted is properly grounded.
Make sure the paint is properly grounded.
The PPH707 painting functions should be disabled when there is no
air movement in the paint booth.
Make sure all items in the paint booth meet the local, regional, and
federal specifications for safety.

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6. Operation
Air Hose Quick Disconnect Fittings
The fittings screw onto the hoses and use and o-ring to seal onto the hose and
prevent the hose from rotating off of the fitting.
The design does not create any restrictions, thus no pressure drop at the
fitting.
The fitting has a hexagon shape to connect to the quick disconnect plate, thus
preventing the hose and fitting from rotating in the quick disconnect.
The fitting goes into an o-ring in the applicator elbow, which seals the
connection even if the elbow is not completed tightened onto the quick
disconnect plate.
The fittings snap into the quick disconnect plate.
Rotation free
Hose
Air
Screwed fitting
O ring

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6. Operation
Fluid Hose Quick Disconnect Fittings
The fittings are composed of two parts. One part has a barb for the hose to go over and
the other part screws onto the other fitting piece. The fluid hose is held from the inside and
outside.
The design of the fitting reduces fluid retention, by means of a rack design and square
section o-ring.
The fitting has a hexagon shape to connect to the quick disconnect plate, thus preventing
the hose and fitting from rotating in the quick disconnect.
Square
Rotation Fitting nut section o-
free ring
Hose
Fluid
O ring

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6. Operation
Bell Speed
Functionality
Before the bell can be spun air is fed
to the turbine, which is directed
directly at the drive shaft and up
towards the bell cup. This causes the Bearing
drive shaft to float on a cushion of air. Air
To spin the bell air is directed into the
back of the fins on the drive shaft.
To slow the bell air is directed into the Turbin
front of the fins on the drive shaft. e Drive
Magnetism is used to “attach” the bell Brak
Air
cup to the drive shaft. e Air

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6. Operation
Remote Bell Cup Sensing

A pressure tap is used to measure a pressure proportional to the bell
cup resistance force.
This pressure must exceed 1,5 bar.
RBC pressure ≤ 0.6 bar
bell cup not present
0.6 bar < RBC pressure < 1.5 bar
Normal
RBC > 1.5 Bar
dirty turbine fastening area
Damage bell cup

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6. Operation
Shaping air 1 Shaping air 2
Shaping Air
Functionality
There are two shaping air circuits
in the PPH 707 SB.
Shaping air 1 consists of hoses
24 A and 24 B.
Shaping air 1 provides the vortex
(angled) airflow.
Shaping air 2 consists of hose 25.
Shaping air 2 provides the straight
airflow.
Both shaping air circuits are within
the same radius around the bell
cup.
This design is patented. Vortex only Combined Air

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6. Operation
Remote Shaping Air Sensing

The pressure tap is used to check flow rate/pressure
Remote shaping
conformity during operation.
air (84)
During production, the pressure can be monitored as a
function of the shaping air 1 flow rate: Shaping Shaping
air 1 Shaping air 1
RSA pressure < Normal air 2
Air leak (shroud incorrectly fastened, punctured
hose, etc.)
RSA pressure > Normal
clogged shaping air holes or kinked hose.

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6. Operation
Loading Paint
Step 1: The dump pilot and trigger Step 2: The paint will begin to flow
pilot are energized. from the selected color valve into the
bell.

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6. Operation
Loading Paint
Step 3: Once material gets close to the Step 4: Once adequate paint goes out of
dump line, the dump pilot is de-energized. the bell the trigger pilot is de-energized.

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6. Operation
Painting
Set the desired bell speed, set the desired shaping air, and energize the trigger pilot.

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6. Operation
Cleaning out Paint
Step 1: Energize the dump pilot and the Step 2: Energize the solvent
trigger pilot. valve on the color changer.

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6. Operation
Cleaning out Paint

Step 3: After some time (time
dependent on the length of hose,
material viscosity, solvent
pressure, etc. ) de-energize the
solvent valve on the color
changer and energize the purge
air valve on the color changer.

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6. Operation
Cleaning out Paint
Step 4: After a period of time (determined Step 5: Repeat steps 3 and 4 as
by testing) de-energize the purge air valve needed to clean out the hosing and
on the color changer and energize the the applicator.
solvent valve on the color changer.

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6. Operation
Cleaning out Paint
Step 6: End the cleaning with the purge Step 7: De-energize the dump pilot
air valve on the color changer energized and the trigger pilot.
for a period of time. This will clear the
hoses and applicator of any remaining
solvent.

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6. Operation
Injector and Bell Cup Wash
Step 1: Energize the injector/bell wash pilot
and the solvent select pilot on the bell wash
valve assembly.
Step 2: The solvent will flow around the

injector and will also come out in a stream from
the shaping air assembly at an angle onto the
bell cup exterior.
Step 3: De-energize the solvent select pilot

and energize the air select pilot on the bell
wash valve assembly.
Step 4: De-energize the injector/bell wash

pilot.

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6. Operation
Atomizer Diagram

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6. Operation
Quick Disconnect Plate Layout
11 Paint 1 25 Shaping Air strait
12 Paint 2 83 Remote Bell Cup
41 Dump 1 84 Remote Shaping Air
42 Dump 2 26 Microphone In
31 Injector/Bell Wash 43 Microphone Out
23 Bearing Air
51 Paint 1 Pilot
52 Paint 2 Pilot
53 Dump 1 Pilot
54 Dump 2 Pilot
58 Injector/Bell Wash Pilot
FO Fiber Optic Connection
21A Turbine Drive Air
21B Turbine Drive Air
22 Turbine Brake Air
24A Shaping Air vortex
24B Shaping Air vortex

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6. Operation
Elbow (at QD) Layout
11 Paint 1 25 Shaping Air 2 Exhaust
12 Paint 2 83 Remote Bell Cup
41 Dump 1 84 Remote Shaping Air 21A 53 FO 21B
42 Dump 2 26 Microphone In 54 84
31 Injector/Bell Wash 43 Microphone Out
23 Bearing Air 24A 25
51 Paint 1 Pilot
24B
52 Paint 2 Pilot
53 Dump 1 Pilot
22 43
54 Dump 2 Pilot 51
58 Injector/Bell Wash Pilot 26
FO Fiber Optic Connection
23
21A Turbine Drive Air 58 52
21B Turbine Drive Air
22 Turbine Brake Air
31 83
41 42
24A Shaping Air 1
11 12
24B Shaping Air 1

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6. Operation
Elbow (at turbine/shaping air) Layout
Turbine Drive Air
Exhaust (21A)
Shaping Air 1 Sense
(84)
Shaping Air 2 (25) Bearing Air (23)
Injector Wash(31) Shaping Air 1

(24A)
Brake Air (22)
Shaping Air 1
FO
(24B) Fluid (Paint) Line
(11 &12)
Microphone In (26)
Air Out (43) Remote Bell Cup
(83)
48
Turbine Drive Air (21B) Bell Wash (31)

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6. Operation Compensation Air

Turbine Layout Exhaust
(not used)
Turbine Drive Air

(21B)
Bearing Air (23)
In (26) Microphone
Brake Air (22) Out (43) Air
Turbine Drive Air

(21B)
Compensation Air
(not used) Remote Bell Cup
49 (83)

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6. Operation
Shaping Air Assembly Layout
Bell Wash (31)

Shaping Air 1
(24B)
Shaping Air 2
(25)
Shaping Air 1
Remote
(24A)
Shaping Air
(84)

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6. Operation
Injector Holder/Injector Layout
Injector Wash
(31)
Fluid (Paint) Line

(11 &12)
51

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1. Installation/removal tool for cover nut, outer
shroud, and nut
• Part number: 90004492
2. Nanovalve removal tool

3. Nanovalve torque tool


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4. Microvalve removal tool

5. Microvalve torque tool

6. Installation tool for fittings

• Part Number: 1313955

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7. Quick Disconnect Fitting Removal Tool

Part Number: 900002665
8. Removal tool for injector

Part Number: 910000700

_______ ________
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9. Magnetic bell cup removal and installation tool.

Part Number
35 mm 50 mm 65 mm 80 mm
900005784 900000803 1204427 1204456

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13. Hose cutter
Part Number: W3SCTU002
14. Screwdriver (small and medium)
15. Allen wrench (2, 2.5, 3 and 4 mm)

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16. Torque wrench
17. Fine brush
18. Flat wrenches

(9, 10, 11, 12 and 13 mm)
18. Cylindrical brush

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Disassembly the bell cup must only be done when shroud is
assembly
Bell Cup Removal

Step 1: Position the tool with the tapered portion towards the stem of the bell cup.
Step 2: Close the tool on the bell cup and pull the bell cup straight out from the shroud
assembly.
Step 3: Keep the tool closed while moving the bell cup (to avoid dropping the bell cup).

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Distributor Removal
Step 1: Using a 5 mm Allen wrench, loosen the deflector by the back of the bell cup.
Caution: left hand threading.

Caution: Deflector and Bell Cup are a matched and balanced set.
Step 2: Extract the deflector from the bell cup.

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Distributor Insertion
Step 1: Carefully place the deflector in the bell cup.
Caution: Deflector and Bell Cup are a matched and balanced set.
Step 2: Turn over the assembly, then using an appropriate wrench, tighten the deflector in
the bell cup with a tightening torque of 3 Nm.

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Attaching the Bell Cup
Step 1: Close the tool around the bell cup and keep closed while moving the bell cup (to
avoid dropping the bell cup).
Step 2: Place the bell cup straight into the shaping air assembly.
Step 3: Once the magnet seats the bell cup, remove the tool.

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Exercise 1
1. Remove the bell cup from the PPH707.
2. Remove the deflector from the bell cup.
3. Insert the deflector into the bell cup.
4. Place the bell cup onto the PPH707.

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Removing the Shaping Air Assembly
Step 1: Remove the bell cup.
Step 2: Push the inner shaping air assembly against the atomizer and remove the shroud
(outer cover) by placing the tool into the wrench notches in the outer cover slots, turn
clockwise and continue removing by hand.
Step 3: Remove the inner shaping air assembly

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Removing the solvent pipette from the elbow

Step 1: Remove bell cup, shaping air assembly, and turbine from the elbow.
Step 2: Remove the solvent pipette using an M1.6 x 0.35 screw.
CAUTION: This operation automatically

destroys the solvent pipette.

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Removing the Microvalves

Step 1: Remove bell cup and shaping air
assembly.
Step 2: Remove white protective cover from
the elbow.
Step 3: Using the disassembly tool, unscrew
the microvalve to disengage the thread.
If the microvalve remains in its housing.
Turn the disassembling tool over.
Screw the tool onto the microvalve.
Inspect Extract the microvalve with a circular
pressure movement.
relief ports

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Removing Nanovalves
Step 1: Remove bell cup and shaping air
assembly.
Step 2: Remove white protective cover from
the elbow.
Step 3: Using the disassembly tool, unscrew
the nanovalve to disengage the thread.
If the nanovalve remains in its housing.
Turn the disassembling tool over.
Screw the tool onto the microvalve.
Inspect Extract the microvalve with a circular
pressure movement.
relief ports

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Removing the Turbine
Step 1: Remove the bell cup and shaping air assembly.
Step 2: Loosen the three turbine fastening screws.
Step 3: Pull turbine straight off from the elbow, taking care not to damage the injector.
Never flush the turbine in solvant.
3 screws

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Removing the Injector and Injector Holder
Step 1: Remove the bell cup, shaping air assembly, and turbine.
Step 2: Use the injector removal tool to loosen the injector. Withdraw the injector from the
diffuser by pulling it carefully.
Step 3: Use a 2.5 mm Allen wrench to remove the three screws holding the injector holder
to the elbow.
Do not use a wrench to

loosen the injector as the
wrench can slip and the
injector can be damaged.

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Removing the Fiber Optic pig tail
Step 1: Remove the elbow from the PPH707.
Step 2: Remove the turbine from the elbow.
Step 3: Remove the end piece at the quick disconnect plate end using a hook and by
pulling under the positioning flat. Push back the two visible fibers inside the elbow.
Step 4: Remove the end piece and its two fibers at the turbine end.
Do not use a hard object as damage to the fibers may occur.

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Inserting the Fiber Optic pig tail
Step 1: Position the new end-piece on the quick-
disconnect plate in the elbow.
Step 2: Insert the two fibers in their housing at turbine
end and push inside elbow.
Note: Make sure both end pieces are pushed in so they
are flush with the elbow.
Step 3: Mount the turbine onto the elbow.
Step 4: Mount the elbow onto the PPH707.

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Mounting the Injector and Injector Holder
Step 1: Use a 2.5-mm Allen wrench to tighten (1.7 Nm torque)
the three screws that attach the injector holder to the elbow.
Step 2: Place the o-ring on the injector holder, place the injector
in the injector holder, then tighten manually until there is
resistance.
Step 3: Screw the injector in the injector holder using the
installation tool and a torque wrench (torque 2.2 Nm).
Step 4: Attach the bell cup, shaping air assembly, and turbine

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Mounting the Turbine
Step 1: Place the turbine on the elbow, taking care
not to damage the injector.
Step 2: Tighten the three turbine fastening screws

to a torque of 2.2 Nm.
Step 3: Attach the bell cup and shaping air

assembly to the PPH707.
3 bolts

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Inserting the solvent pipette into the elbow

Step 1: Push the new solvent pipette into the elbow.
Step 2: Attach bell cup, shaping air assembly, and turbine to the elbow.

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Inserting Nanovalves into the Elbow
Step 1: Using the disassembly tool, screw the Nanovalve into the elbow.
Step 2: Switch to the Nanovalve tightening tool attached to a torque wrench and tighten
the Nanovalve to 2.5 Nm.
Step 3: Place the white protective cover onto the elbow.
Step 4: Attach the bell cup and shaping air assembly to the elbow.

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Inserting Microvalves into the Elbow
Step 1: Using the disassembly tool, screw the Microvalve loosely into the elbow.
Step 2: Switch to the Microvalve tightening tool attached to a torque wrench and tighten the
microvalve to 2.5 Nm.
Step 3: Place the white protective cover onto the elbow.
Step 4: Attach the bell cup and shaping air assembly to the elbow.

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Mounting the Shaping Air Assembly
Step 1: Check for the presence of the o-ring on the inner shaping air assembly.
Step 2: While lining up the indexes push the inner shaping air assembly until it stops.
Step 3: Place the shroud over the inner shaping air assembly, secure it by hand then
tighten it with the tool.
Step 4: Attach the bell cup
Intérieur
Intérieur

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Exercise 2
1. Remove the shaping air assembly from the PPH707.
2. Remove the turbine from the PPH707.
3. Remove the injector from the PPH707.
4. Remove the injector holder from the PPH707.
5. Return the PPH707 to working condition.

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Removing the Elbow

Step 1: Hold the elbow and loosen the cover using the removal tool. The rear split ring
must be perfectly positioned.

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Removing the Cover Nut
Step 1: Remove the elbow.
Step 2: Slide the large split ring out of the slot in the cover and onto the back portion of the
cover so as to allow the cover to slide upward.
Step 3: Remove the small split ring.
Step 4: Slide the cover nut forward and off from the rear support.

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Removing the Fiber Optic Cable from the Quick Disconnect Plate
Step 1: Remove the elbow and the UHT 157.
Step 2: Use a small screw driver to move the flag of the fiber optic cable out of the quick
disconnect plate.
Step 3: Disconnect the fiber optic cable from the fiber optic pickup and pull out of the quick
disconnect.

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Removing the UHT 157 Cascade
Step 2: Loosen the fastening screw on the quick disconnect plate that retains the UHT 157
high-voltage unit.
Step 3: Pull the high-voltage unit straight out of the robot support and quick disconnect plate.

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Removing Hoses from the Quick Disconnect Plate
Step 2: Position the fitting removal tool on to the fitting and rotate the tools to attach the tool.
Step 3: Pull the tool with the fitting attached straight out of the quick disconnect plate.

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Removing Air Fittings From Hoses
Step 1: Remove the elbow from the PPH707 and the hose fitting from the quick disconnect
plate.
Step 2: Insert the hose in the orifice corresponding to the hose diameter in the fitting installation
tool and close the tool. While firmly holding the tool loosen the fitting using a flat wrench.

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Remove Fluid Fittings From Hoses
Step 1: Remove the elbow from the PPH707 and the hose fitting from the quick disconnect
plate.
Step 2: Loosen the nut while holding the fitting with two flat wrenches, then withdraw the
fitting from the tube by pulling (slightly rotating the fitting).

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Replacing fittings
Step 1: Remove the elbow from the PPH707, the hose from the quick disconnect plate, and
the fitting from the hose.
Step 2: Cut the hose approximately 20 mm from its end using the tube cutter.
Step 3:
• Air fitting: Push the hose into the fitting and rotate to tighten.
• Fluid fitting: Fit the nut on the hose, push the hose onto the fitting body to the shoulder,
and tighten the nut.

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Replacing hosing
Step 1: Remove the elbow from the PPH707, the hose from the quick
disconnect plate, and the fitting from the hose.
Step 2: Connect the new hose to the robot arm end of the old hose
and pull the old hose through the quick disconnect plate until the new
hose protrudes from the quick disconnect plate.
WARNING : Replace all hoses every 12 to 24 months, depending on the amount of use.

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Removing Quick Disconnect Plate
Step 1: Remove the elbow from the PPH707.
Step 2: Loosen the two fastening screws (M5x15) and
pull the quick disconnect plate away from the rear
support.
Step 3: In order to pull the quick disconnect completely
off from the rear support the hoses need to be
disconnected from either the other end or the fittings in
the quick disconnect removed from the hoses.

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Removing the Coil Block
Step 1: Remove the elbow and the cover nut from the PPH707.
Step 2: Use a 4-mm Allen wrench to loosen the two coil block fastening screws.
Step 3: Use a 9-mm flat wrench to loosen the two fluid input coil block fittings, and pull the
two hoses from the block.
Step 4: Loosen the coil fittings using an 11 mm flat wrench, and pull the coils from the block.
Step 5: Use a 3 mm Allen wrench to loosen the nipple, and pull it from the coil.

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Removing the Coil
Step 1: Remove the elbow, and the cover nut from the PPH707.
Step 2: Use a 4-mm Allen wrench to loosen the two coil block fastening screws.
Step 3: Loosen the coil fittings using an 11 mm flat wrench, and pull the coils from the
block.
Step 4: Loosen the quick disconnect plate fittings with the tool and use two flat wrenches
to loosen the fitting so it can be pulled from the hose.
Step 5: Unwind the hose from the rear support.

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Removing the low voltage connection
Step 1: Remove the elbow, and the cover from the PPH707.
Step 2: Use the 3 mm Allen wrench to loosen the two
retaining screws on the side of the rear nut.
Step 3: Spin the rear nut until the rear support is no longer
attached.
Step 4: Move the rear support to the side and loosen the low
voltage connection fastening screws (two M5x12 screws).
Step 5: Disconnect the low voltage cable from the opposite
end and pull through the robot wrist.

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Removing the rear support
Step 1: Remove the elbow, the cover nut, coil
block hose connections, and the low voltage
connection from the PPH707.
Step 2: Use the 3 mm Allen wrench to loosen the
two retaining screws on the side of the cover.
Step 3: Use the cover removal tool to turn the
cover in the direction of the Loosen Arrows
shown on the cover. Pull the rear support away
from the cover.

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Removing the Mounting Nut and Robot Adapter
Step 1: Remove the elbow, the cover nut, low
voltage connection, coil block hose connections,
and the rear support from the PPH707.
Step 2: Use the appropriate Allen wrench to
remove the screws holding the robot adapter to the
robot.
Step 3: When the robot adapter is free of the robot
slide the cover off.

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Mounting the Mounting Nut and Robot Adapter
Step 1: Slide the cover onto the robot adapter.
Step 2: Use the appropriate Allen wrench to
tighten the screws holding the robot adapter to the
robot.
Step 3: Mount the elbow, the cover nut, low
voltage connection, coil block hose connections,
and the rear support onto the PPH707.

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Mounting the rear support
Step 1: Push the rear support onto the cover. Use the removal tool to turn the cover in the
direction opposite of the Loosen Arrows shown on the cover until tight.
Step 2: Use the 3 mm Allen wrench to tighten the two retaining screws on the side of the
cover.
Step 3: Mount the elbow, the cover nut, coil block hose connections, and the low voltage
connection onto the PPH707.

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Mounting the low voltage connection
Step 1: When removing the old low voltage connection, connect a fish tape to the end of
the low voltage cable on the other side of the robot wrist.
Step 2: Attach the new low voltage cable to the fish tape. Pull the low voltage cable
through the robot wrist and place onto robot adapter.
Step 3: Tighten the low voltage connection fastening screws (two M5x12 screws).
Step 4: Mount the rear support, elbow, and the cover nut onto the PPH707.

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Mounting the Coil
Step 1: Connect the fluid fittings to the hose and push the hose back through the quick
disconnect plate.
Step 2: Wind the coils around the rear support exactly as shown in the two illustrations.
The two coils must not touch each other and they must be wound without gaps in order
to install the outer cover.
Step 3: Place the two fitting nuts on the two coils, connect the two coils to the block, and
tighten the two nuts.
Step 4: Place the elbow, the cover nut, and the coil block onto the PPH707.

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Mounting the Coil Block
Step 1: Twist the nipple into hose coil.
Step 2: Push the coils into the block and tighten the coil
fittings using an 11 mm flat wrench.
Step 3: Push the two hoses from the wrist into the block
and use a 9-mm flat wrench to tighten the two coil block
fittings.
Step 4: Use a 4-mm Allen wrench to tighten the two coil
block fastening screws.
Step 5: Mount the elbow and the cover nut onto the
PPH707.

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Mounting the Quick Disconnect Plate
Step 1: Push the quick disconnect plate towards the rear support and tighten the
two fastening screws (M5x15) when the quick disconnect plate is seated in the rear
support.
Step 2: Mount the elbow onto the PPH707.

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Inserting the Fiber Optic Cable into the Quick Disconnect Plate
Step 1: Cover the loose fiber optic cable ends with a hose taped to the fiber optic cable
hose.
Step 2: Pull the hose taped to the fiber optic cable through the quick disconnect until the
fiber optic cable is fully seated in the quick disconnect.
Step 3: Remove the hose covering the fiber optic cable loose fibers and connect the fibers
into the fiber optic pick up.
Step 4: Reinsert the UHT 157 and attach the elbow.

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Inserting Hoses into the Quick Disconnect Plate
Step 1: Position the trapezoidal fitting tool on to the fitting and rotate the tool grab the
fitting.
Step 2: Push the tool with the fitting attached straight into the quick disconnect plate.
Step 3: Remove the fitting tool from the fitting.
Step 4: Attach the elbow.

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Inserting the UHT 157 Cascade

Step 1: Push the high-voltage unit straight into the robot support and quick disconnect
plate.
Step 2: Tighten the fastening screw on the quick disconnect plate that retains the UHT 157
high-voltage unit.
Step 3: Reattach the elbow.

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Mounting the Cover nut
Step 1: Slide the cover assembly onto the rear support so that the quick disconnect plate is
not covered.
Step 2: Place the smaller split ring onto the quick disconnect plate.
Step 3: Slide the larger split ring off from the outer portion of the cover and back into the slot
in the cover.
Step 4: Mount the elbow.

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Mounting the Elbow

Step 1: Hold the elbow and tighten the cover using the removal tool.

TRAINING
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Exercise 3
1. Remove the cover nut from the PPH707.
2. Remove the UHT 157 cascade from the PPH707.
3. Change an air hose and fitting on the PPH707.
4. Change a fluid hose and fitting on the PPH707.
5. Remove the Fiber Optic cable from the PPH707.
6. Remove the quick disconnect plate from the PPH707.
7. Change a coil on the PPH707.
8. Remove the coil block from the PPH707.
9. Remove the Low Voltage connection from the PPH707.
10. Return the PPH707 to working condition.

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Component Type of Task Frequency
Bell Cup Cleaning/Inspection Daily
Shaping Air Exterior Cleaning/Inspection Daily
Shaping Air Assembly Cleaning/Inspection Weekly
Injector Exterior Cleaning/Inspection Weekly
Coil Block Cleaning/Inspection Monthly
Turbine Cleaning/Inspection Every 3 months
Injector Assembly Cleaning/Inspection Every 3 months
O-rings Replacement As needed
Nanovalves Replacement After 2,500,000 cycles
Microvalves Replacement After 3,000,000 cycles
Turbine Replacement As needed
Air fittings in QD Replacement As needed
Fluid fittings in QD Replacement As needed
UHT 157 Cascade Replacement As needed
Quick Disconnect plate Replacement As needed
Coil Replacement Yearly
Low voltage cable Replacement 1 to 2 years

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Nuts and screws :
- Tightening check once a year
UHT157 :
- Live time > 10000H
- Change the cable 1x/year*
Elbow :
- External cleaning (daily)
- Change valves after 2 millions cycles
Coil :
- Change the coil 1x/year
Q-D plate:
- Fitting > 10000H
- Check the O-ring 1x/ year
- Change the hoses 1x/ year
High speed turbine :

Shroud air:
- External cleaning 1x/ year
- Live time = 7 years warranty
Bell :
- Live time = 1 an*

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Daily Maintenance and Cleaning
Cleaning of atomizer exterior, outer shaping air shroud, and bell cup exterior.
1. Clean the outer cover and the bell cup exterior with a clean cloth.
2. Check that the grooves on the outer cover are clean.
3. Dry carefully.

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Weekly Maintenance and Cleaning
Cleaning of bell cup.
1. Remove the magnetic bell cup using tool.
2. Carry out a visual inspection.
3. Let the bell cup soak for one hour in an appropriate solvent,
then clean with a clean cloth and soft brush.
4. Dry carefully with compressed air.
5. Reinstall the bell cup.

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Cleaning of shaping air assembly.
1. Remove the bell cup.
2. Begin to loosen the outer cover with tool, then continue
manually.
3. Remove the outer shaping air shroud, then remove the inner
shaping air shroud.
4. Carry out a visual inspection of the three components, replace
if necessary.
5. Let the outer cover soak in solvent for one hour, then clean the
outer and inner surfaces with a clean cloth soaked in solvent.
6. Use a nylon brush to clean the holes on the front face of the
outer cover.
7. Clean carefully with compressed air (concentrating on the
holes to eliminate paint residues), then wipe with a clean, dry
cloth Reinstall the shaping air assembly onto the PPH707.

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Cleaning of injector exterior.
1. Remove the bell cup and shaping air shroud
assembly.
2. Use a brush slightly soaked in solvent to clean
the injector exterior.
3. Dry carefully with a clean, dry, non-fluffy
cloth.
4. Inspect the injector assembly for damage or
being off center. Replace if necessary.
5. Reinstall the bell cup and shaping air
assembly.

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Quarterly Maintenance and Cleaning
Cleaning of turbine.
1. Remove the bell cup, shaping air assembly, and
the turbine.
2. Clean the turbine interior with a cylindrical brush.
3. Clean the turbine exterior with a soft, non-fluffy
cloth.
4. Prior to reinstalling the turbine on the elbow,
check the condition of the O-rings, replace them if
necessary, and make sure that they are all
present.
5. Remount the turbine, shaping air assembly, and
bell cup.

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Quarterly Maintenance and Cleaning
Cleaning of injector and injector holder.
1. Remove the bell cup, shaping air assembly,
turbine, and injector assembly.
2. Clean the injector with a soft brush that was
soaked in solvent.
3. In case of significant buildup, let the injector soak
for one hour in an appropriate solvent and dry
carefully with compressed air.
4. Check the condition of the injector O-rings.
Replace them if necessary.
5. Remount the injector assembly, turbine, shaping
air assembly, and bell cup.

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12. System Test Procedures

Bell Speed Control System
Step 1: Make sure the main power is on.
Step 2: Open the cover over the bell speed control card.
Step 3: Set the bell speed control card mode switch to Local.
Step 4: Slowly move the bell speed potentiometer from 0 to 3.
Assessment:
If the bell speed feedback system is OK the bell speed display will settle in on a value
near 30,000.
If the bell speed spins at a high velocity but the display only shows around 13,000,
there is a problem with either the fiber optic pigtail within the PPH707 or with the
target on the back side of the turbine.
If the under speed LED on the bell speed control card is on, then there is more than
likely a problem with the turbine.
Step 5: Continue the testing by checking the bell speed with the potentiometer set to 4, 5,
and 6.
Step 6: Move the bell speed potentiometer to 0.
Step 7: Set the bell speed control card mode switch to Remote.

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Shaping Air System
Step 1: Lock out the robot according to the local rules and regulations.
Step 2: From the robot or GUI screen force a value to shaping air #1.
Assessment 1: Move to the applicator and verify the air is coming out the correct set of
holes (angled for SA 1, straight for SA2).
Assessment 2: Note the value indicated on the flow meter.
If the value is more than 10% off from the set point
Recalibrate the flow meter.
Change the set point so the transducer is fully opened, change the transducer if
the flow is less than 600 L/min.
Repeat Step 2 and Assessment 2 with additional shaping air values.

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Injector/Bell Wash
Step 2: Remove the bell cup from the applicator.
Step 3: Force on the injector/bell wash solvent.
Step 4: Force on the injector/bell wash nanovalve.
Assessment: View the streams of solvent leaving from the applicator. One stream
should be around the injector and the other should be angled towards the bell cup.

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Trigger
Step 2: Remove the bell cup from the applicator.
Step 3: Force on the solvent at the color changer.
Step 4: Force on the trigger microvalve.
Assessment: View the applicator, there should be a steady stream coming out of the
injector.
Step 5: Replace the bell cup onto the applicator.

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Dump
Step 2: Force on the solvent at the color changer.
Step 3: Find the dump return hose and disconnect it at a union.
Step 4: Force on the dump nanovalve.
Assessment: View the dump, there should be a steady stream coming out of the hose.
Step 5: Reconnect the dump line at the union.

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13. Troubleshooting
Paint Finish Issues
Irregular atomization
Cause: Dirty bell cup serrations.
Remedy: Clean or replace bell cup.
Air entrapment
Cause: Damaged bell cup.
Remedy: Replace bell cup.

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13. Troubleshooting
Pattern Control
Uneven pattern
Cause: Dirty or damaged shaping air ring.
Remedy: Clean or replace shaping air ring.
Pattern too large

Cause: Loose shaping air shroud.
Remedy: Tighten shaping air shroud.
Cause: Bell Speed too high.

Remedy: Lower bell speed set point.
Cause: Shaping air value is too low.

Remedy: Increase shaping air set point.
Cause: Shaping air hose leak.

Remedy: Find leak and repair it/replace hose.

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13. Troubleshooting
Pattern Control
Bell Speed Control
No bell speed.
Cause: Turbine dirty or damaged.
Remedy: Clean or replace turbine.
Cause: Brake air is on.

Remedy: Replace brake air solenoid, replace the bell speed control board.

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13. Troubleshooting
Pattern Control
Bell Speed Control
Uncontrolled bell speed
Cause: Damaged/defective target on the turbine.
Remedy: Replace turbine.
Cause: Damaged/defective turbine.

Remedy: Replace the turbine.
Cause: Wire(s) from microphone cable into the terminal strip are loose.
Remedy: Tighten the terminals holding the wire(s).
Cause: Wire(s) from the bell speed feedback cable into the terminal strip are
loose.
Remedy: Tighten the terminals holding the wire(s).

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13. Troubleshooting
Pattern Control
Bell Speed Control
Uncontrolled bell speed
Cause: Damaged/defective bell speed feedback cable.
Remedy: Replace the bell speed feedback cable.
Cause: Pin in the back of BSC-100 is not properly seated into the connector.
Remedy: Properly seat the connector.
Cause: Damaged/defective pin in the BSC-100 connector.

Remedy: Replace the pin and seat it correctly.
Cause: BSC-100 not properly seated into the rack.

Remedy: Reseat the BSC-100 into the rack and rotate the four retaining posts
90 °.
Cause: Damaged/defective BSC-100.

Remedy: Replace the BSC-100.

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13. Troubleshooting
Pattern Control
Bell Speed Control
Bell speed is below set point.
Cause: Brake air is on.
Remedy: 1. Replace brake air solenoid.
2. replace the bell speed control board.
Cause: Low or no bearing air.

Remedy: 1. Repair/replace the bearing air hose.
2. Set bearing air regulator to at least 80 psi.
3. replace bearing air regulator.
Cause: Insufficient air volume for turbine drive.

Remedy: 1. Repair/replace the turbine drive air hoses.
2. Replace bell speed transducer.
Cause: Dirty or damaged turbine.

Remedy: Replace turbine.

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13. Troubleshooting
Pattern Control
Bell Speed Control
Bell speed is below set point.
Cause: Damaged/defective transducer.
Remedy: Replace transducer.
Paint Flow Issues
No paint coming out of the applicator.
Cause: Damaged/disconnected trigger pilot hose.
Remedy: Replace/repair the air hose.
Cause: The supply air pressure is less than 90 psi.

Remedy: Increase the supply air pressure.
Cause: The microvalve control rod is jammed.

Remedy: Replace the microvalve.

TRAINING
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13. Troubleshooting
Paint Flow Issues

Paint leaking out of the applicator when the trigger is off.
Cause: The pilot solenoid to the trigger microvalve is remaining on.
Remedy: Replace the trigger pilot solenoid.
Cause: The microvalve return spring is broken.
Cause: The microvalve control rod is jammed.
Cause: The microvalve needle is dirty.
Remedy: Clean the needle seat surface and the needle.
Cause: The microvalve needle is defective/damaged.

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13. Troubleshooting
Injector/Bell Wash Issues
No solvent coming out of the applicator.
Cause: Damaged/disconnected injector/bell wash pilot hose.
Remedy: Replace/repair the air hose.
Cause: The supply air pressure is less than 90 psi.

Remedy: Increase the supply air pressure.
Cause: The nanovalve control rod is jammed.

Remedy: Replace the nanovalve.

TRAINING
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13. Troubleshooting
Injector/Bell Wash Issues
Solvent leaking out of the applicator when the trigger is off.
Cause: The pilot solenoid to the injector/bell wash nanovalve is remaining on.
Remedy: Replace the injector/bell wash pilot solenoid.
Cause: The nanovalve return spring is broken.

Cause: The nanovalve control rod is jammed.

Cause: The nanovalve needle is dirty.

Remedy: Clean the needle seat surface and the needle.
Cause: The nanovalve needle is defective/damaged.


TRAINING
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Course Review
6. Operation
12. Troubleshooting

TRAINING
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Post Test and Course Survey
Please answer all questions to the best of your ability.

The purpose of the post test is to compare the results to that
of the pre test to determine the effectiveness of the course.
The tests are to evaluate the instructor, not the students.
We appreciate all comments good or bad.

PPH 707 SB Applicator Training Course

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PPH 707 SB Applicator Training Course

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TRAINING

PPH 707 SB Applicator

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This course provides the detailed instruction and procedures

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1. Know what the PPH 707 is used for.

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Course Outline/Table of Contents

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Please answer all questions you know the answers to and

The purpose of the pretest is to get a baseline of the class’

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The PPH 707 SB is the next generation solvent based paint

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2. Applications Where Used

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The PPH 707 is comprised of two assemblies.

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Shaping Air Assembly

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Injector and Injector Holder

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Small Split Ring

Large Split Ring

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Quick Disconnect Plate

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UHT 157 Cascade

Low Voltage Connection

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Robot Path Velocity

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Dimensions and TCP Values

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Bell Cup Safety

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Nanovalve and Microvalve safety

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Remote Bell Cup Sensing

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Remote Shaping Air Sensing

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