The World of Automation and Consumables Solutions The World of Automation and Consumables Solutions Spraying Technology Manifolds, Spray Heads, & Accessories SH-3000 Single Opposed Nozzle Outlets SH-3000 DE Or SH-3000 DC Nozzle Design Dual Side-by-Side Nozzle Outlets SH-3004 Dual Opposed Nozzle Outlets SH-3004 QE or SH-3004 QC Nozzle Design Quad Side-by-Side Nozzle Outlets
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Spraying Technology - Industrial Innovations World of Automation and Consumables Solutions Spraying Technology Manifolds, Spray Heads, & Accessories SH-3000 Single Opposed Nozzle Outlets
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The World of Automation and Consumables SolutionsThe World of Automation and Consumables Solutions
Spraying TechnologyManifolds, Spray Heads,
& Accessories
SH-3000 Single Opposed Nozzle Outlets
SH-3000 DE Or SH-3000 DC Nozzle DesignDual Side-by-Side Nozzle Outlets
SH-3004 Dual Opposed Nozzle Outlets
SH-3004 QE or SH-3004 QC Nozzle DesignQuad Side-by-Side Nozzle Outlets
The World of Automation and Consumables SolutionsThe World of Automation and Consumables Solutions
• Dual or Quad spray heads are available.
• Spray heads guaranteed against leakage or failure for one million cycles.
• Available in 2, 3, 4, head confi guration.
• Manifold includes blow-off-ports.
See back for more complete information and specifi cations.
The Advance Products Robot Spray Manifold was specifi cally designed to meet the challenging requirements of the die casting industry.
Quad Spray Heads(RSM-4-Q-NPT shown)
Dual Spray Heads(RSM-4-D-NPT shown)
Robot Spray ManifoldsRobot Spray Manifolds
Conf igurat ions
RSM-(A)-(B)-(C) EXAMPLE RSM-4-Q-NPT
ANUMBER OFSPRAY HEADS
2-5
BTYPE OFSPRAY HEADS
D-DUAL SH-3000DCQ-QUAD SH-03004QC
CSTANDARD
NPT USBPT BRITISH
8968 Wide Fan
8980 90° Fan
8975 Oval
8969 90° Cone
*8977 Medium Cone
8967 Medium Fan
8948 Fine Fan
*NOTE: All spray heads come with nozzle #8977 cone style.Advance Products spray nozzles can be used with any of the robotic spray manifold.
NEED A VALVE PACK AGE?Advance offers updated pre-packaged air, lube,blow off with regulators and gages.
RSM-4-Q-NPT shownUS Standard
AIR BLAST - 4 PLCS1/8 NPT TUBE FITING
AIR BLAST CONNECTION1/2 MJIC 1/4 NPT
LUBE CONNECTION3/8 MJIC 3/8 NPT
SPRAY AIR CONNECTION 1/2 MJIC 3/8 NPT
SH-3004QC -QUAD HEAD - COVER SIDESH-3000DC - DUAL HEAD- COVER SIDE
SPRAY AIR CONNECTION 3/8 BSP TAPPED HOLEFOR A HOSE FITTINGBRITISH STANDARD LUBE CONNECTION 3/8
BSP TAPPED HOLEFOR A HOSE FITTINGBRITISH STANDARD
AIR BLAST CONNECTION 3/8 BSP TAPPED HOLEFOR A HOSE FITTINGBRITISH STANDARD
AIR BLAST - 4 PLCS 1/4 BSP TAPPED HOLEFOR A TUBE FITTINGBRITISH STANDARD
RSM-4-Q-BPT shownBritish Standard
9” 0”4”6 1/2” 1 1/2” Spray manifold to robot adapters are available.
4x o 1/4” 13/16” 5/16-18 UNC - 2B 5/8” USED FOR MOUNTING
Printed in U.S.A.Specifi cations are subjectto change without notice. APC-000-2010
Why Proper Manifolds and Accessories Are Important
Consistency, repeatability, and effi ciency - three things all die casters want in their spraying systems. To achieve all three requires the proper spraying equipment. After selecting an automatic die spray system, the spraying package is the most important next step.
The manifold is the heart of the die casting spray system. Manifold selection, along with the choice of spray heads and nozzles, are signifi cant factors in achieving optimum die spraying.
Too often, little consideration is given to manifold design and usage. When you consider that spraying is the most time consuming part of the total casting cycle, it is important to select a manifold that will:
• reduce cycle time• give you a consistent, quality part• reduce labor• be easy to maintain• will not leak
Production Improvements - Cycle Time
As a rule of thumb, spraying should be less than 20% of total cycle time. Many die casters are spraying for 30-40% of the cycle time, which is a huge waste of time. Many years ago, Advance devised a formula that works well in determining proper spraying time. The formula states you should spray one second for every 100 ton of the size of the die cast machine. Add one second per slide and one second for a second spray zone. For example, for an 800-ton DCM with two zones and two slides, your spray time is:
1 sec. x 8 + 1 (additional zone) + 2 (slides) = 11 seconds.
Positioning Accuracy
Digital servo control gives Advance reciprocatorspositioning accuracy within .020”. This repeatabilityis important for maintaining control of the process.
• reduce cycle time• give you a consistent, quality part• reduce labor• be easy to maintain• not leak
Business Side
Quality Issues
How you spray determines the quality of your part. Proper spraying:
• Produces more consistent, shippable parts• Produces more presentable, shiny parts• Reduces scrap• Increases die life• Increases machine up-time
It is important to understand that quality drives production schedules, which translates into MONEY. If you have consistent, quality parts, it is easier to calculate the number of shippable parts made per hour. This translates into better prediction of shipping schedules, which, in turn, controls production schedules.
Environmental and Safety Issues
In addition to producing more shippable parts and reducing labor, automatic spraying is safer than hand spraying. Automatic spraying it takes the operator away from the fumes and the opening and closing of the die casting machine. This can reduce workers’ compensation premiums and make for a safer plant environment.
Summary
Proper automatic spraying with the right manifold, spray heads, and nozzles will reduce cycle time and labor and give you more consistent, usable parts. It is this consistency, repeatability, and effi -ciency of automatic spraying that make it so vital to your production and your bottom line.
AUTOMATION MEANSConsistency
Process RepeatabilityEffi ciency
Safer EnvironmentMore Shippable Part
Better SchedulingMore Profi ts
Manifold Design/Selection
How to DesignYour Manifold
(1) Determine the relative size of the manifold. Use either the die layout drawing, actual casting size, etc.
(2) Determine where you need to spray the die. Highlight the problem areas that may need more cooling.
(3) Decide how you want to spray the die. For example, is a bar (sweep) manifold suit-able or is a more complex Picture Frame®
manifold needed? Do you want to spray with one or two zones of spray?
Single Bar, Single Spray Zone
Single Bar, Dual Spray Zone
Dual Bar, Dual Spray Zone
LGTH PART#
13” 9805 19” 9806
LGTH PART#
25” 9807 31” 9808
LGTH PART#
13” not available 19” 9806
LGTH PART#
25” 9807 31” 9808
LGTH TOP BTM
25” 9807 9816 31” 9808 9818
LGTH TOP BTM
13” 9805 9812 19” 9806 9814
Picture Frame® Manifolds
If your die is more complex or you want to spray the die from one fi xed point, a Picture Frame® Manifold may be suitable. They are our most popular manifolds and come in a multitude of standard sizes to fi t most any application. (See chart at right).
Picture Frame®
Manifolds typically produce the shortest spray time. They are available in both single and dual zone capability.
17 x 1117 x 1417 x 1717 x 2017 x 2317 x 2617 x 2923 x 1123 x 1423 x 1723 x 2023 x 2323 x 2623 x 2923 x 3229 x 1129 x 1429 x 1729 x 2029 x 23 29 x 2629 x 2929 x 3229 x 3535 x 1135 x 1435 x 1735 x 2035 x 2335 x 2635 x 2935 x 3235 x 35
Components Requiredfor Each Assembly
Top Frame Part # Bottom Frame Part # Side Frame Part # Zone 1 Zone 2
Let’s look at some accessories that can help you in the placement of the spray heads. At Advance, we believe that permanent designed manifolds are better than extension tubes coming out of the head.
Hard manifolds do not go out of adjustment and make die changeover quick. Also, with Advance’s straight-in-the-die travel, reciprocator die openings can be reduced. This produces greater die spraying effi ciency and less over spray and run off. By reducing the die spray opening needed, faster cycle rates can be achieved.
STANDOFFS are available in 1-inch increments and are supplied with O-rings and bolts.
ON-PLANE T’s can beattached to the end of the exten-sion providing the availability of two spray heads from one spray head location. Come complete with O-rings and fasteners.
OFF-PLANE T’s attach to the end of the extension and are used to project two spray heads toward the die cavity. Comes complete with O-rings and fasteners.
OFF-PLANE T’S
LENGTH PART # 6-inch 4072-6
ON-PLANE T’S
4924CORNERGUSSET
4924CORNERGUSSET
TOPMANIFOLD
BOTTOMMANIFOLD
4072-6ON-PLANE
T
4073-6OFF-PLANE
T
4952STANDOFF
SIDEMANIFOLD
4688-XXAIR
BLAST
4914CORNERBLOCK
4914CORNERBLOCK
0921-024ALIGNMENT
SLEEVE
0118-020SOCKET
HEADCAP SCREW
4071STANDOFF
4067BLANKING
PLATE
4079O-RINGS
QC-0913-MFQUICK CHANGE
MANIFOLD ADAPTER
QUICK CHANGE MANIFOLD ADAPTERS allow for fast manifold exchange without tools for quick and easy die setup.
LENGTH PART # 6-inch 4073-6
• Wide range of spray volumes from ultra-fi ne mist toheavy dosing.
• Not dependent on the same air and lube pressures.In fact, the independent air and lube pressurescan vary from 40 to 110 psi without affecting each other.
• .5 gpm per each nozzle outlet.• No-leak construction GUARANTEED. Advance’s new
positive shutoff doesn’t permit leaking.• Either internal or external mix nozzle outlets can be
used on the same head. An Advance exclusive!• All internal parts are warranted for 1,000,000 cycles
against leakage. Body warranted for 10 years.
FEATURES
Model 3000 Spray Heads
After years of research and development, Advance, the industry leader in spraying technology, has developed the ultimate spray head for die spraying; the Advance ModelSH-3000 spray head.
The Model SH-3000 has fewer parts and an improved design. Adjustablility is greatly improved with a full three-turn range compared to 1-1/2 on the Model 2000. There is also improved atomization consistency over a larger variation of air to lube pressure.
The Model SH-3000 offers a wide range of spray patterns with nine interchangeable nozzles from ultra-fi ne mist to maximum output. Various extension tubes are also available. Air and lube pressures can be set independently and are adjustable from 40 to 110 psi.
The spray head is also retrofi ttable on any of our spraying reciprocators. Manifold conversions are availabe for any brand of sprayer.
All internal parts are warranted for 1,000,000 cycles. The spray head body has a 10-year warranty.
Spray Head Foot Print1-1/2” x 2”
8962 (O-ring)
050-0089(Needle Assembly)
8949 Needle 8983 O-ring
8953 (Nozzle Seat)*Nozzle 8977
(Standard)8959 (Set Screw)
9926 (Poppit Assembly) 8966 Rubber Seat
8955 Spray Head Poppit
8963 (O-ring)
8984 (O-ring)
10463 (Conical Spring)
8960 (Socket Head Cap Screw)
8950 (Top Cap)
8947 (Body SH-3000 Opposed)
8970 (Nozzle Retainer)
8975 Oval
*8977 Medium Cone
8969 90° Cone
8948 Fine Fan
8968 Wide Fan
8980 90° Fan
8967 Medium Fan
SH-TUBE-001 1/4” O Tube (2”)
SH-TUBE-002 1/4” O Tube (4”)
SH-TUBE-003 1/4” O Tube (6”)
DUAL NOZZLE DESIGN
Need more lube in a concentrated area? Try the new Advance Dual Nozzle spray head, ideal for ejector side.The head features two nozzles on one side of the head and comes with two nozzles of your choice.
To order SH-3000 Spray Head with specifi c nozzles, other than the standard #8977, cross reference spray head with the desired nozzle:
Figure 4: SH-TUBE-007, SH-TUBE-008, and SH-TUBE-009 consist of: 4079 (O-ring), 9649 (adapter noz-zle to tube), 5998 (adapter 1/8 mnpt to 1/4 tube), 9628-016(2” tube), 9628-032 (4” tube), 9628-048 (6” tube).
• Wide range of spray volumes from ultra-fi ne mist toheavy dosing.
• Not dependent on the same air and lube pressures.In fact, the independent air and lube pressurescanvary from 40 to 110 psi without affecting each other.
• .5 gpm per each nozzle outlet.• No-leak construction GUARANTEED. Advance’s new
positive shutoff doesn’t permit leaking.• Either internal or external mix nozzle outlets can be
used on the same head. An Advance exclusive!• All internal parts are warranted for 1,000,000 cycles
against leakage. Body warranted for 10 years.
The Model SH-3004 has fewer parts and an improved design. Adjustablility is greatly improved with a full three-turn range compared to 1-1/2 on the Model 2000. There is also improved atomization consistency over a larger variation of air to lube pressure.The Model SH-3004 offers a wide range of spray patterns with nine interchangeable nozzles from ultra-fi ne mist to maximum output. Various extension tubes are also available. Air and lube pressures can be set independently and are adjustable from 40 to 110 psi.The spray head is also retrofi ttable on any of our spraying reciprocators. Manifold conversions are availabe for any brand of sprayer.All internal parts are warranted for 1,000,000 cycles. The spray head body has a 10-year warranty.
FEATURES
Model 3004 Spray Heads
SH-TUBE-001 1/4” O Tube (2”)
SH-TUBE-002 1/4” O Tube (4”)
SH-TUBE-003 1/4” O Tube (6”)
*8966 Rubber Seat*8955 Spray Head Poppit
*8949 Needle*8983 O-ring
8960(Socket Head Cap Screw)
8950 (Top Cap)
10463 (Conical Spring)
8984 (O-ring)
9926 (Poppet Assembly)
8963 (O-ring)
050-0089 (Needle Assembly)
12240 (Body SH-3004)
8959 (Set Screw)
8962 (O-Ring)
8953 (Nozzle Seat)
Spray Head Foot Print1-1/2” x 2”
*Nozzle 8977 (Standard)
8975 Oval
*8977 Medium Cone
8969 90° Cone
8948 Fine Fan
8968 Wide Fan
8980 90° Fan
8967 Medium Fan
8970 (Nozzle Retainer)
QUAD NOZZLE DESIGNNeed more lube in a concentrated area? Try the new Advance Quad Nozzle spray head, ideal for ejector side.The head features four nozzles on one side of the head and comes with four nozzles of your choice.
Quad Nozzle DesignDual Opposed Nozzle Outlets
Model 3004 Spray Heads
Nozzle Design SH-3004 Quad Nozzle SH-3004 Quad Nozzle Ejector Side Cover Side
Description Spray Gun Handle, Complete Nozzle 14” Chrome Tubing Model HSG-14 20” Chrome Tubing Model HSG-20 25-1/2” Chrome Tubing Model HSG-25 Lever Cotter Pin Lube Cap Lube Valve Air Cap Without Ring Lube Valve Spring Lube Regulating Screw Air Regulating Screw Air Valve Air Valve Spring Lube Hose Connector (1/8” Barb I.D.) Air Hose Connector (1/4” Barb I.D.) Air Nipple Lube Nipple