Ransburg 78011-XX User Manual
Ransburg
MODULAR COLOR CHANGER
SERVICE MANUAL
CS-01-01.8
(Replaces CS-01-01.7)
March - 2013
MCV SERIES
MODEL(S): 78011-XX
IMPORTANT: Before using this equipment,
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
Service Manual Price: $30.00 (U.S.)
MCV Color Changer
NOTE: This manual has been changed from CS-01-01.7 to revision CS-01-01.8. Reasons for this
change are noted under “Manual Change Summary” page 33 of this manual.
Ransburg
CS-01-01.8
MCV Color Changer - Contents
CONTENTS
SAFETY: 1-5
SAFETY PRECAUTIONS ......................................................................................................1
HAZARDS / SAFEGUARDS ..................................................................................................2-5
INTRODUCTION: 6-9
DESCRIPTION ......................................................................................................................6
SPECIFICATIONS .................................................................................................................7
MCV PRE-ENGINEERED COLOR CHANGER ASSEMBLIES / PARTS LIST .....................8-9
MCV COLOR CHANGE MATRIX ...........................................................................................9
INSTALLATION: 10-11
MCV INSTALLATION PROCEDURES ..................................................................................10-11
OPERATION: 12-13
Ransburg
PAGE
OPERATING ..........................................................................................................................12-13
MAINTENANCE: 14-19
GENERAL MAINTENANCE ..................................................................................................14-15
79239-XX REGULATOR DISASSEMBLY / REASSEMBLY PROCEDURE ..........................16-17
REGULATOR REASSEMBLY PROCEDURE .......................................................................17
TEST AND CHECKOUT PROCEDURE FOR COLOR CHANGER ......................................18-19
PARTS IDENTIFICATION: 20-31
MCV COLOR CHANGER ASSEMBLY / PARTS LIST .......................................................... 20-21
78075-00 & 78075-02 BELL WASH ASSEMBLIES / PARTS LIST ....................................... 22
78075-01 & 78075-03 BELL WASH ASSEMBLIES / PARTS LIST ........................................ 23
78070-00 BLOCK PURGE ASSEMBLY / PARTS LIST ........................................................ 24
MANIFOLD ASSEMBLY / PARTS LIST ................................................................................ 25
79239-XX REGULATOR ASSEMBLY / PARTS LIST ........................................................... 26-27
FLOW METER BLOCK ASSEMBLY / PARTS LIST ............................................................. 28
78949-00 VALVE & 77367-00 SEAT REPLACEMENT PARTS / PARTS LIST ..................... 29
77620-00 VALVE PLUG KIT (OPTIONAL ) / PARTS LIST ................................................... 29
78074-00 OUTLET BLOCK ASSEMBLY / PARTS LIST ....................................................... 30
78235-00 REGULATOR & FLOW METER STAND-ALONE ASSEMBLY .............................. 31
79245-00 REGULATOR DR 2 STAND-ALONE ..................................................................... 31
WARRANTY POLICIES: 32
LIMITED WARRANTY ...........................................................................................................32
CS-01-01.8
MCV Color Changer - Safety
SAFETY
Ransburg
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature for your Ransburg products. This manual
contains information that is important for you to
know and understand. This information relates to
USER SAFETY and PREVENTING EQUIPMENT
PROBLEMS. To help you recognize this information, we use the following symbols. Please pay
particular attention to these sections.
A WARNING! states information to alert you
to a situation that might cause serious injury
if instructions are not followed.
A CAUTION! states information that tells how
to prevent damage to equipment or how to
avoid a situation that might cause minor injury.
A NOTE is information relevant to the procedure in progress.
W A R N I N G
!
The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
This manual MUST be read and thor-
oughly understood by ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGS and safety requirements for
operating and servicing the equipment are
followed. The user should be aware of and
adhere to ALL local building and re codes
and ordinances as well as NFPA-33 SAFE-
TY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
W A R N I N G
!
While this manual lists standard specications
and service procedures, some minor deviations
may be found between this literature and your
equipment. Differences in local codes and plant
requirements, material delivery requirements,
etc., make such variations inevitable. Compare
this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences.
Careful study and continued use of this manual
will provide a better understanding of the equip-
ment and process, resulting in more efcient
operation, longer trouble-free service and faster,
easier troubleshooting. If you do not have the
manuals and safety literature for your Ransburg
system, contact your local Ransburg representative or Ransburg.
The hazards shown on the following pag-
es may occur during the normal use of this
equipment. Please read the hazard chart beginning on page 2.
1
CS-01-01.8
Ransburg
MCV Color Changer - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent arcing that is capable of
causing re or explosion is
lost if any safety interlocks
are disabled during operation. Frequent Power Supply
or Controller shutdown indicates a problem in the system
requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Fire extinguishing equipment must be present in
the spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray
area.
The high voltage supplied to the atomizer must
be turned off prior to cleaning, ushing or maintenance.
When using solvents for cleaning:
• Those used for equipment ushing should
have ash points equal to or higher than
those of the coating material.
• Those used for general cleaning must have
ash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be maintained during cleaning operations using ammable or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but
only as instructed.
Non-factory replacement parts or unautho-
rized equipment modications may cause re or
injury.
If used, the key switch bypass is intended for
use only during setup operations. Production
should never be done with safety interlocks disabled.
Never use equipment intended for use in waterborne installations to spray solvent based materials.
The paint process and equipment should be
set up and operated in accordance with NFPA33, NEC, OSHA, local, country, and European
Health and Safety Norms.
CS-01-01.8 2
MCV Color Changer - Safety
Ransburg
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Explosion Hazard
Improper or inadequate operation and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are disabled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system requiring correction.
SAFEGUARDS
Tells how to avoid the hazard.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction.
General Use and
Maintenance
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
Always turn the control panel power off prior to
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no
objects are within the safe sparking distance.
Ensure that the control panel is interlocked with
the ventilation system and conveyor in accordance with NFPA-33, EN 50176.
Have re extinguishing equipment readily available and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be
read and understood prior to using this equipment.
Comply with appropriate local, state, and national codes governing ventilation, re protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
3
CS-01-01.8
Ransburg
MCV Color Changer - Safety
AREA
Tells where hazards
may occur.
Spray Area /
High Voltage
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled insulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the applicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray
area, with the exception of those objects required by the process to be at high voltage, must
be grounded. Grounded conductive ooring
must be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or working on spray system equipment.
Unless specically approved for use in hazardous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33.
CS-01-01.8 4
MCV Color Changer - Safety
Ransburg
AREA
Tells where hazards
may occur.
Electrical
Equipment
HAZARD
Tells what the hazard is.
Electrical Discharge
High voltage equipment is utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. Personnel are exposed to
high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shutdown indicates a problem in the
system which requires correction.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
Unless specically approved for use in hazardous locations, the power supply, control cabinet,
and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN
50176.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combustible material.
Testing may require high voltage to be on, but
only as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
Toxic Substances
Spray Area
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-Trichloroethane are not chemically
compatible with the aluminum
that might be used in many system components. The chemical
reaction caused by these solvents reacting with aluminum
can become violent and lead to
an equipment explosion.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manufacturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
Aluminum is widely used in other spray application equipment - such as material pumps,
regulators, triggering valves, etc. Halogenated
hydrocarbon solvents must never be used with
aluminum equipment during spraying, ushing,
or cleaning. Read the label or data sheet for the
material you intend to spray. If in doubt as to
whether or not a coating or cleaning material is
compatible, contact your coating supplier. Any
other type of solvent may be used with aluminum
equipment.
5
CS-01-01.8
Ransburg
INTRODUCTION
MCV Color Changer - Introduction
DESCRIPTIONS
The MCV Color Changer is a material valve
stack used to control material ow to an applicator
or other material supply equipment. The stack
assembly is made up of several sub-assembled
stacks which are then connected together.
A description of stacks are as follows:
• Attached Bell Wash Module - These may
be attached to the main stack. Both avail-
able assemblies contain external check
valves on the inlet parts to prevent back
ow of material.
• Stand Alone Bell Wash Module - These
may be mounted seperatly away from the
stack assembly. An external outlet port is
included to provide a connection to an
applicator or other such device. Both
available assemblies contain external
check valves on the inlet ports to prevent
back-ow of material.
NOTES
• 2 - Color Block Module
• 4 - Color Block Module
• 8 - Color Block Module
• Inline DR-2 Regulator with performance
matching the industry standard
Ransburg DR-1 regulator
• Flow Meter Module for use with bottom
ported uid ow meters.
The 78949-00 Microvalve was designed to trigger
up to 2-million cycles. The uid and air sections
are separated by a weep port to prevent contam-
ination between air and uid.
CS-01-01.8 6
MCV Color Changer - Introduction
SPECIFICATIONS
Electrical / Physical
Ransburg
2-Color Modular Changer
Size: 4” wide (10.16cm)
3 3/4” High (9.53cm)
1 1/4” Long (3.8cm)
Weight: 0.98 lbs. (0.44 Kg)
16-Color Modular Changer
Size: 4” Wide (10.16cm)
3 3/4” High (9.53cm)
12 1/4” Long (31.1cm)
Weight: 9.8 lbs. (4.45 Kg)
Operating Pressure:
Fluid 300 psi max.
(20.68 bar)
Operating Temperature
Range: 55°F (12.8°C)
130°F (54°C)
Actuation Tube: 5/32” (4mm) OD
Air Actuating
Pressure: 75-120 psi (5.2-8.3 bar)
Average Flow
Rate:
@80 psi (50 centipoise)
Maximum Number
of Colors: 32
Construction
Materials: Stainless Steel UHMW
DR-2 Regulator
Air Pressures: Variable by Control
(Manual or Automatic)
100 psi (7 bar max.)
Fluid Input: 300 psi (20.7 bar max.)
(10 psi min. above output
pressure)
Fluid Output: Variable by Ratio
Pneumatic Connections
Air Pilot: 1/8” NPT (F) Thread (Cap)
#10-32 (F) Thread (Plate)
Volume of Paint Held
Within Regulator: 5 cc
202 . oz./6000cc per min
Regulator Performance
The 78239-XX regulator performance matches that of the stand-alone DR-1. Figures X and Y show
the performance curves associated with the 78239-XX regulator.
Figure X Figure Y
7
CS-01-01.8
Ransburg
MCV PRE-ENGINEERED
COLOR CHANGER
ASSEMBLIES
The following is for “pre-engineered” color
changer assemblies. Please reference “MCV
Color Changer Matrix” for the changer assembly
number.
MCV Color Changer - Introduction
Figure 1: MCV Pre-Engineered Color Changer Assemblies
CS-01-01.8 8
MCV Color Changer - Introduction
MCV COLOR CHANGER - PARTS LIST (Figure 1)
Ransburg
Item #
1 78077-00 Check Valve Assembly
2 78075-00 Attached Cup Wash Assembly with 2 Check Valves
3 78070-00 Purge Valve Assembly with 2 Check Valves
4 78071-00 2-Color Block Assembly
5 78072-00 4-Color Block Assembly
6 78073-00 8-Color Block Assembly
7 79239-XX DR-2 Regulator Assembly
8 78076-00 Flow Meter Block Less Flow Meter
9 78074-00 Outlet Block Assembly
10 77957-00 Retaining Clip, Color Changer
11 78078-00 Tool, Retaining Clip Removal
13 78099-00 Inlet Plug Assembly
14 78069-00 Fluid Regulator Inlet Tube
15 78114-00 Coupling, 1/4” NPS (F) X 3/8” NPS (F)
16 74151-XX DR-1 Fluid Regulator (See “DR-1Regulator” Service Manual for details)
17 A10756-00 Tool, Valve Removal
18 78096-00 3/8” NPS (F) X CAP
19 A10766-00 Tool, Valve Seat Removal
20 78098-00 1/8” NPT (M) X 3/8” NPS (M)
21 78097-00 3/8” NPS (M) X 3/8” NPS (F), 90° Elbow
22 75955-06 “AW” Flow Meter - Consult Sales Rep. for Pick-Up
Part #
Description
MCV COLOR CHANGER MATRIX:
Model No. 78011 - XX X X X X X X X
Denotes Color Selector Including:
1 Solvent Air Purge Assembly (78070)
2 Check Valve Assembly (78077)
1 Outlet Assembly (78074)
Number of Colors:
(Maximum of 32 Colors)
Fluid Supply:
0 = Circulating Paint Supply
1 = Dead Headed
2 = Dead Headed With Check Valves
(78077 Assembly)
Fluid Fitting:
0 = 3/8” NPS Fitting
Flow Meter Type:
0 = No Flow Meter
1 = Block With Flow Meter Attached
2 = Block With No Flow Meter
Air Push Assembly (Assemblies
consist of Color Valve, Check
Valve, Regulator, Gage & Fitting):
0 = No Air Push Assembly
1 = 1 Air Push Assembly
2 = 2 Air Push Assemblies
Attached Cup Wash Assembly:
0 = None
1 = One Assembly (78075-00)
Fluid Regulator DR-1 Type:
0 = No Regulator 4 = 1:4 Ratio
1 = 1:1 Ratio 5 = 1:6 Ratio
2 = 1:2 Ratio 6 = 1:8 Ratio
3 = 1:3 Ratio 7 = 1:10 Ratio
Fluid Regulator DR-2 Type:
0 = No Regulator 4 = 1:4 Ratio
1 = 1:1 Ratio 5 = 1:6 Ratio
2 = 1:2 Ratio 6 = 1:8 Ratio
3 = 1:3 Ratio 7 = 1:10 Ratio
4 = 1:4 Ratio
9
CS-01-01.8
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