Ransburg 78715 User Manual
TURBODISK
ASSEMBLY
SERVICE MANUAL
LN-9240-02.1
(Replaces LLN-9240-02.1)
January - 2013
MODELS: 78715
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: $50.00 (U.S.)
CONTENTS
SAFETY:
Turbodisk 2 - Contents
PAGE
1-7
SAFETY PRECAUTIONS.........................................................
HAZARDS / SAFEGUARDS.....................................................
GENERAL SAFETY GUIDELINES...........................................
INTRODUCTION:
FEATURES................................................................................
GENERAL DESCRIPTION.......................................................
SPECIFICATIONS.....................................................................
TYPICAL SPEED CHART (RPM'S)..........................................
INSTALLATION:
EQUIPMENT..............................................................................
AIR CONTROL..........................................................................
MOUNTING................................................................................
INTERLOCKS............................................................................
TYPICAL TURBODISK 2 DRIVE AIR SYSTEM & AIR LOGIC CONTROL
PANEL........................................................
UPPER TURBODISK 2 BULKHEAD PLATE...........................
TURBODISK 2 SIGNAL / PORT IDENTIFICATION TABLE...
OPERATION:
COATING MATERIALS.............................................................
FLUID FLOW CONTROL..........................................................
FLUID VALVE CONTROL.........................................................
FLUID & AIR PRESSURE REQUIREMENTS..........................
TURBINE SPEED......................................................................
ELECTROSTATIC VOLTAGE..................................................
TARGET DISTANCE.................................................................
1
2
5
8-11
8
8
9
10
12-15
12
12
12
12
13
14
15
16-19
16
16
17
17
18
19
19
MAINTENANCE:
GENERAL..................................................................................
CLEANING PROCEDURES.....................................................
VIBRATION NOISE...................................................................
TURBINE REPAIR & REBUILD...............................................
VALVES & REGULATORS.......................................................
PREVENTIVE MAINTENANCE................................................
DISASSEMBLY PROCEDURES..............................................
TROUBLESHOOTING GUIDE.................................................
NO VALVE APPLICATION SCHEMATIC................................
3-WAY VALVE APPLICATION SCHEMATIC..........................
TRIGGER / DUMP w/REGULATOR SCHEMATIC.................
TRIGGER / DUMP w/REGULATOR (DR-1) SCHEMATIC.....
LN-9240-02.1
20-33
20
20
22
22
22
22
23
28
30
31
32
33
(CONTINUED ON NEXT PAGE)
Turbodisk 2 - Contents
PARTS IDENTIFICATION:
PAGE
34-69
TURBODISK 2 ASSY MODEL IDENTIFICATION...................
TURBODISK 2 ASSY, NO VALVES / PARTS LIST................
TURBODISK 2 ASSY, 3-WAY VALVE / PARTS LIST.............
TURBODISK 2 ASSY, TRIGGER & DUMP VALVE W/FLUID REGULATOR
/ PARTS LIST....................................................
TURBODISK 2 ASSY, TRIGGER & DUMP VALVE W/DR-1 FLUID REGU-
LATOR / PARTS LIST........................................
LOWER TURBODISK 2 FLUID CONTROL ASSEMBLY / PARTS LIST........
......................................................................
UPPER TURBODISK 2 BULKHEAD PLATE & FAIRING MOUNTING /
PARTS LIST.......................................................
FLUID SUPPLY LINE PACKAGE / PARTS LIST....................
3-WAY VALVE ASSY / PARTS LIST........................................
HIGH FLOW FLUID REGULATOR ASSY / PARTS LIST.......
DR-1 FLUID REGULATOR ASSY / PARTS LIST...................
DR-1 FLUID REGULATOR ASSY / PARTS LIST...................
TURBODISK 2 AIR HEATER / PARTS LIST...........................
TURBODISK 2 QUICK RELEASE FAIRING ASSY /
PARTS LIST..............................................................................
TRIGGER & DUMP VALVE ASSY / PARTS LIST...................
BULKHEAD PLATE FITTING LAYOUT / PARTS LIST...........
TURBODISK 2 AIR TURBINE ASSY / PARTS LIST...............
34
38
40
42
44
46
48
50
52
54
56
58
60
62
64
66
68
WARRANTY POLICIES:
LIMITED WARRANTY...............................................................
APPENDIX:
PAINT AND SOLVENT SPECIFICATIONS.............................
VISCOSITY CONVERSION CHART........................................
VOLUMETRIC CONTENT OF HOSE OR TUBE.....................
70
70
71-74
71
72
74
LN-9240-02.1
SAFETY
SAFETY PRECAUTIONS
Turbodisk 2 - Safety
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.
While this manual lists standard specications and
service procedures, some minor deviations may be
found between this literature and your equipment.
Dierences 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
dierences.
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 thoroughly
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 SAFETY
STANDARD, 2000 EDITION, prior to installing,
operating, and/or servicing this equipment.
W A R N I N G
!
> The hazards shown on the following page may
occur during the normal use of this equipment.
Please read the hazard chart beginning on page
2.
Careful study and continued use of this manual will
provide a better understanding of the equipment and
process, resulting in more ecient 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.
1LN-9240-02.1
Turbodisk 2 - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate opera-tion
and maintenance procedures will
cause a re hazard.
Protection against inadver tent
arcing that is capable of causing
re or explosion is lost if any safety
interlocks are disabled during
operation. Frequent power supply
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 o 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 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA 33, 2000 Edition, OSHA and local codes.
In addition, ventilation must be maintained during
cleaning operations using ammable or combustible
solvents.
General Use and
Maintenance
Improper operation or maintenance
may create a hazard.
Personnel must be properly trained
in the use of this equipment.
Electrostatic arcing must be prevented.
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 unauthorized
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.
Personnel must be given training in accordance with the
requirements of NFPA 33, Chapter 16, 2000 edition.
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. OSHA references
are Sections 1910.94 and 1910.107. Also refer to
NFPA 33, 2000 edition and your insurance company
requirements.
2
LN-9240-02.1
Turbodisk 2 - Safety
AREA
Tells where hazards
may occur.
Electrical Equipment
HAZARD
Tells what the hazard is.
High voltage equipment is utilized.
Arcing in areas of ammable or
combustible materials may occur.
Personnel are exposed to high
voltage during operation and
maintenance.
Protection against inadver tent
arcing that may cause a fire 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 coating
mater ials and cause a fire or
explosion.
SAFEGUARDS
Tells how to avoid the hazard.
The power supply, optional remote control cabinet, and
all other electrical equipment must be located outside
Class I or II, Division 1 and 2 hazardous areas. Refer to
NFPA No. 33, 2000 Edition.
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.
Explosion Hazard /
Incompatible
Materials
Toxic Substances
Halogenated hydrocarbon solvents
for example: methylene chloride
and 1,1,1,-Trichloro-ethane 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.
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
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 material supplier.
Any other type of solvent may be used with aluminum
equipment.
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.
LN-9240-02.1
3
Turbodisk 2 - Safety
AREA
Tells where hazards
may occur.
Spray Area / High
Voltage Equipment
Personnel Safety /
Mechanical Hazards
HAZARD
Tells what the hazard is.
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.
The disk atomizer can rotate at
speeds up to 40,000 RPM. At these
speeds, the edge of the applicator
can easily cut into skin. Loose
articles can also be caught by the
rotating disk.
SAFEGUARDS
Tells how to avoid the hazard.
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 megohm.
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.
Any person working in the spray area must be
grounded.
Unless specically approved for use in hazardous
locations, the power supply and other electrical control
equipment must not be used in Class 1, Division 1 or
2 locations.
Personnel must stay clear of the disk whenever it is
rotating.
Before touching the disk, the turbine air must be shut
o.
If the disk has been rotating, allow at least three minutes
for it to come to a complete stop before touching it.
4
LN-9240-02.1
Turbodisk 2 - Safety
GENERAL SAFETY GUIDELINES
• The articles being coated MUST be grounded at all
times.
W A R N I N G
!
> The simple safety measures outlined here
are vital. Failure to observe them could cause a
spark capable of starting a re.
• All components of the applicator system (except the
atomizing head) MUST be grounded at all times.
• All contact points MUST be free of any accumulation
of nonconductive residue.
• All electrically conductive objects, especially solvent
containers within the spray area, MUST be either
removed or grounded.
Any tool, if used improperly, can be dangerous. Safety
is ultimately the responsibility of those using a tool.
In like manner, safe operation of electrostatic coating processes is the responsibility of those who use
such processes and those who operate electrostatic
coating equipment. Procedures to be followed on
conducting electrostatic coating operations safely are
outlined in the Ransburg brochure IL-247: "Operating
Your Electrostatic Coating System Safely". Additional
copies are available from Ransburg upon request.
All personnel connected with coating operations
should read and understand this brochure. It is
most important that the equipment operators and
supervisory personnel understand the requirements
for safe operation.
W A R N I N G
!
Additional cards summarizing these safety requirements are available from Ransburg on request. These
cards should be posted in the spraying area so that
they can be readily referred to and serve as a reminder
to personnel in that area of responsibility. Additional
copies of the sign SL-00-07: "Cleaning Safety Requirements" are available upon request.
Each user should examine his own coating operation,
develop his own safety program, and ensure that his
workers follow correct procedures. Ransburg hopes
that the information it provides is helpful to the user
in establishing such a program.
In addition to the available cards, labels, brochures,
and service manuals, the user should consult other
standards and recognized safety authorities. Section
1910.107 of the regulations established under the
Occupational Safety and Health Act [OSHA] apply to
spray nishing operations. Paragraph (i) specically
applies to electrostatic hand spraying equipment.
NFPA No. 33 "Spray Application", is another standard
for spray painting operations. Chapters 9, 10, and
13 are specically applicable to electrostatic coating. Copies of NFPA No. 33 are available from the
National Fire Protection Association, Batterymarch
Park, Quincy, Mass. 02269 (at nominal cost).
The National Fire Protection Association also publishes standards other than NFPA No. 33 relating to
the control of re hazards. NFPA No. 33 specically
refers to the following bulletins of the National Fire
Protection Association as applicable to coating operations:
NFPA No.63: Dust Explosion, Industrial Plants
NFPA No.70: National Electrical Code
NFPA No.86A: Ovens and Furnaces
NFPA No.91: Blower and Exhaust Systems
NFPA No.654: Dust Explosions, Plastics Industry
NFPA No.77: Static Electricity, also contains much
useful information. Copies of these brochures will be
helpful in arriving at a program for safe operation.
> If ANY symptom of improper operation
occurs, suspend use of the unit until the problem
has been diagnosed and corrected. See the
appropriate "Troubleshooting Guide" or contact
your Ransburg representative.
LN-9240-02.1
Local codes and authorities also have standards to be
followed in the operation of your spray equipment.
Your insurance carrier will be helpful in answering
questions that arise in your development of spray
coating procedures.
5
Turbodisk 2 - Safety
All personnel MUST read and understand the
following Ransburg Safety Publications:
IL-247: Operating Your Electrostatic Coating System
Safely SL-77-01: Personnel Grounding
Ransburg also suggests that all personnel read the
HEW publication "Spray Painting: Good Practices for
Employees", number (NIOSH) 78-178 available from
the regional NIOSH oce or the U.S. Government
Printing Oce.
NIOSH and OSHA regional offices can provide
information on OCCUPATIONAL SAFETY AND
HEALTH ACT, including questions on standards
interpretations, voluntary compliance information,
copies of the OSHA Standards, OSHA Act, Employee
Rights Posting Notice and Publications.
Personnel
• All personnel should read and understand local
codes, appropriate NFPA bulletins, OSHA Act of
1970, and this service manual.
Parts
• Articles being painted MUST be grounded at
ALL times. Paint MUST NEVER be permitted to
accumulate on workholders, particularly on points
where workholders touch conveyor. Hooks MUST
be clean to ensure proper contact. It is advisable to
have extra sets of workholders to enable cleaning of
the sets not being used at regular intervals. Areas
of hanger contact should be sharp points or edges
where possible.
• All electrically conductive objects within the
spray area (including spray booth, paint tank, and
conveyor) MUST BE GROUNDED. This requirement
applies to the solvent safety container, paint
containers, wash cans, and all other objects in the
area.
Ventilation
We recommend interlocking the ventilation with the
spraying equipment to ensure proper ventilation
when equipment is in operation. See NFPA Bulletin
No. 33.
• Personnel working in the spray area MUST be
adequately grounded. Insulated shoes such as
rubber, composition, or cork soles should NOT
be worn unless an alternate grounding method
is provided. (See Ransburg Bulletin SL-77-01,
"Personnel Grounding".)
W A R N I N G
!
> ALWAYS turn power supply OFF prior to
cleaning or working on equipment.
> ENSURE that the grounding hook has been
properly secured to the motor housing.
• Personnel working on applicators MUST always
be sure that the high voltage is o, the rotator has
stopped and that the grounding hook has been
properly secured to the motor housing.
Housekeeping
• Good housekeeping is essential to safe operation.
Clean-up and maintenance schedules should be
established by the user, based on observations of
the initial production operations. Maintenance and
safety cards should be posted in clear view of the
operator.
• Normal re protection measures are required.
These include proper storage of paints, solvents,
and waste, plus ready access to re extinguishing
equipment. For details, consult NFPA Bulletins No.
30, 33, 70 and 77, your local re codes, local paint
equipment standards, OSHA Act of 1970, and your
insurance carrier’s recommendations.
Floor Covering and Masking
If it is necessary to cover booth ooring, Ransburg
suggests that the user employ a material which will
NOT support combustion, such as Spark Gard Grade
BWA-100.
6
LN-9240-02.1
Turbodisk 2 - Safety
Halogenated Hydrocarbons
W A R N I N G
!
> A chemical reaction, resulting in the
possibility of a pressure EXPLOSION, may occur
if 1,1,1-Trichloroehtane, Methylene Chloride, or
other Halogenated Hydrocarbon solvents are
used in PRESSURIZABLE FLUID SYSTEMS having
ALUMINUM or GALVANIZED WETTED PARTS.
Such an explosion could cause DEATH, serious
BODILY INJURY, and/or substantial property
damage. See Ransburg Bulletins:
SL-81-05: HHC Explosion Hazard Danger Sign
SL-81-08: HHC Explosion Hazard Safety Bulletin
Consult your uid supplier to determine the
chemical content of your solvents.
NOTES:
LN-9240-02.1
7
Turbodisk 2 - Introduction
INTRODUCTION
FEATURES
Features which make the Turbodisk
advantageous for use in electrostatic applications
include:
• Proven turbine motor reliability.
• Patented serrated edge conical disk provides
excellent atomization quality at minimal rotational
speeds.
• Aerodynamic fairing design for ease of cleaning of
external surfaces.
• Speed readout (or control) uses reliable magnetic
pickup for ber-optic transmission of rotational
speed data. (optional)
• A majority of all assembly components which
come in contact with the uid material are made
of either stainless steel or, which is impervious to
most uids.
• Negligible maintenance down time. With the quick
disconnect feature, the lower Turbodisk 2 uid
section can be exchanged in minimal time for o
line maintenance.
• Quick disconnect feature allows for other uid
control assemblies to be incorporated when
desired.
TM
2 Applicator
GENERAL DESCRIPTION
The Turbodisk 2 Applicator, because of it's high
rotational speed, produces finer atomization,
improved quality, and higher transfer eciency with
any of the wide variety of coating materials (such
as waterborne and high solids) used in production
nishing operations. It's speed is controlled by varying
the drive air. The applicator assembly is designed for
use on vertical overhead mounted reciprocators.
Quick Disconnect
-REFER TO FIGURES 16, 17, & 26
The Turbodisk 2 Applicator is a quick disconnect
design that allows the lower uid section that carries
all the uid/ air controls to be separated from the
upper section carrying the tubing supply lines. The
incoming air lines, uid lines, high voltage cable,
and ber optic cable are connected to the ttings
provided on the upper xed bulkhead plate. Each
bulkhead plate (upper and lower) utilizes special
male and female ttings with o-rings that seal the
uid and air line passages when both sections are
assembled together. Two latching mechanisms have
been incorporated into the design allowing the lower
section to be supported while the operator tightens or
loosens the retaining screws that hold the upper and
lower sections together. Alignment arrows engraved
into the side of the bulkhead plates provide for quick
visual assembly orientation.
• The easily removable lower fairing, turbine air motor
assembly, and the externally mounted regulators
and uid valves, make o line maintenance more
ecient and economical.
• Control air lines are color coded for ease of
identication.
• Higher uid delivery rates can be achieved using a
dual feed uid system.
• High ow regulators and uid valves provide for
simultaneous paint push out while solvent washes
the feed tube and disk.
8
Conical Disk Assembly
The Turbodisk 2 Applicator uses conical disk
assemblies that are made from high grade aluminum
construction and are force balanced to .10 grams•in or
better. With the patented serrated edge, these disks
come in sizes of 6, 9, and 12 inch diameters.
LN-9240-02.1
Turbodisk 2 - Introduction
Turbodisk 2 Fairing
-REFER TO FIGURE 24
The Turbodisk 2 Applicator fairing is required for
safe operation. The two piece fairing provides high
voltage isolation from the metal rotator assembly
and valve components, as well as ease of cleaning
and maintenance. Provided on the fairing are (4)
draw latches which allow for easy on/o removal of
the lower fairing.
W A R N I N G
!
> Both sections of the fairing to be in place
when the Turbodisk 2 is in operation or when
high voltage is supplied to the applicator.
Paint Valve Options
Four paint valve options in single or dual feed
applications are available:
SPECIFICATIONS
Mechanical
Turbine Speed: Variable to 40,000 rpm
max. (6" conical disk)
Turbine Type: Ball Bearing
Weight: 57 lbs. (approximately)
Length: 36 in.
Diameter: 13.25 in.
Turbine Air: At max. speed (40krpm),
requires 103.1 psi and
61.1 scfm, unloaded
(see Figure 1)
Fluid Pressure
Inlet: See Figure 4
• No Valves (refer to Figures 7,12,18)
• 3-Way On/O Valve (refer to Figures 8,13,19)
• Trigger and Dump Valve with High Flow Regulator
(refer to Figures 9,14,20,25)
• Trigger and Dump Valve with Low Flow
Regulator (refer to Figures 10,15,21,22,25)
Power Supply and Controls
In the system, the high voltage is supplied to the
Turbodisk 2 by either the MicroPak™ Industrial power
supply system or a Voltage Master™ series power
supply.
The MicroPak Indus trial power supply uses
proven high voltage generator technology that
is microprocessor controlled for diagnostics and
communication. The controller is packaged in
standard rack mounted Eurocard format for easy
access and system integration.
The Voltage Master™ power supplies are general
purpose heavy duty power supplies with years of
proven reliability. They have variable voltage control,
many safety features, and remote analog voltage
control capabilities.
Single Fluid Flow Range:
Waterborne: To 1,200 cc/min.
Solvent Base: To 1,500 cc/min.
High Solids: To 1,000 cc/min. (80%+)
Air Inlet Trigger/
Dump: 70-100 psi
Air Pilot for Fluid
Pressure: See Figure 4
Electrical
Power Supply MicroPakTM Industrial
or Type: Voltage Master
Charging Method: Direct
Input Voltage: 0-100 kV
Turbine Speed
Control or Monitor: PulseTrackTM
(Optional)
TM
LN-9240-02.1
9
Turbodisk 2 - Introduction
NOTES:
TYPICAL SPEED CHART (RPM's)
-REFER TO FIGURES 1 & 23
The following represents data collected under lab
conditions. Flow meters were installed on each of
the two 3/8 I.D. heated air lines used to supply the
Turbodisk 2 turbine motor. The airow through
each ow meter was recorded and added together
to obtain the total air ow through the system. The
speed of the disk was monitored through the means
of a PulseTrack™ system. The air heater was set at 120
degrees during all data collection.
Rotational speeds are unloaded and can be expected
to drop 20 to 30% when under a uid load condition.
Heated turbine air increases eciency of motor up
to 10%. This chart should be used as a guide ONLY.
Speeds will vary due to rotator wear, tubing size or
lengths, etc.
NOTE
> Never run disk over it's maximum safe
operating speed.
10
LN-9240-02.1
TYPICAL SPEED CHART - 10 HOLE ORIFICE PLATE
6" Conical Disk
Turbodisk 2 - Introduction
Disk Speed
(RPM)
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
9" Conical Disk
Disk Speed
(RPM)
5,000
10,000
Supply Air
Pressure (PSI)
6.6
10.5
18.2
27.8
40.4
56.3
76.4
103.1
Supply Air
Pressure (PSI)
11.3
26
Air Flow #1
(SLPM)
140
190
260
340
440
560
730
930
Air Flow #1
(SLPM)
200
330
Air Flow #2
(SLPM)
100
140
200
260
350
460
610
800
Air Flow #2
(SLPM)
140
250
Total Air Flow
(SLPM)
240
330
460
600
790
1,020
1,340
1,730
Total Air Flow
(SLPM)
340
580
Total Air Flow
(SCFM)
8.5
11.7
16.2
21.2
27.9
36.0
47.3
61.1
Total Air Flow
(SCFM)
12.0
20.5
13,000
16,000
19,000
22,000
12" Conical Disk
Disk Speed
(RPM)
2,000
4,000
6,000
8,000
10,000
12,000
12,500
39.5
55.4
79.8
102
Supply Air
Pressure (PSI)
8.7
18.6
31.0
48.3
68.5
95.8
102.0
430
560
760
930
Air Flow #1
(SLPM)
170
270
370
500
670
880
930
340
460
640
800
Air Flow #2
(SLPM)
120
200
290
400
560
750
780
770
1,020
1,400
1,730
Total Air Flow
(SLPM)
290
470
660
900
1,230
1,630
1,710
27.2
36.0
49.4
61.1
Total Air Flow
(SCFM)
10.2
16.6
23.3
31.8
43.4
57.6
60.4
LN-9240-02.1
Figure 1: Typical Speed Chart - 10 Hole Orice Plate
11
Turbodisk 2 - Installation
INSTALLATION
EQUIPMENT
This system should be installed by, or under the
supervision of an Ransburg representative. Should the
need arise to replace any component assembly within
the system, contact your Ransburg representative.
This manual concerns normal operation, maintenance,
and service of the specied applicator assemblies. The
air and uid connections vary with dierent models
and installations. This manual deals primarily with
those at, or within the assembly.
AIR CONTROL
-REFER TO FIGURE 2
Air control of the applicator is from a standard
Ransburg air logic panel, which includes two lters
(one 40 micron lter located at the air logic station
and one 5 micron lter located at the inlet of the inline air heater panel). Clean, dry factory air must be
provided to the inlet lter of the air logic station via
a minimum 1/4-inch I.D. pipe and to the inlet lter of
the heater panel via a minimum 3/4-inch I.D. pipe.
MOUNTING
-REFER TO FIGURE 17 & 24
The Turbodisk 2 assembly is mounted on the
reciprocator using (4) 5/16-18 screws provided on
the ram ange. Loosening (2) 1/4-20 screws on the
same ram ange will allow the assembly to rotate.
Position the Turbodisk 2 assembly so that the strain
relief boot is positioned toward the incoming uid
and air lines and retighten.
Remove lower fairing by releasing the (4) quick release
draw latches. Thread all the required air, high voltage,
ber optic, and uid service lines through the strain
relief boot. The strain relief boot may have to be cut
larger in order to feed all the lines through. Refer to the
78718 assembly/schematic diagram for connection
reference to upper bulkhead plate.
Reinstall lower fairing. Install conical disk and torque
to 50-60 lb•in.
INTERLOCKS
Flow of coating material should be locked out unless
all of the following conditions are met:
12
1. Booth exhaust is turned on.
2. The turbine is spinning.
3. High voltage is on or in the bypass mode.
LN-9240-02.1
Turbodisk 2 - Installation
Figure 2: Typical Turbodisk 2 Drive Air System and Air Logic Control Panel
TYPICAL TURBODISK 2 DRIVE AIR SYSTEM & AIR LOGIC CONTROL PANEL - PARTS
LIST (Figure 2)
Item # Part # Description Qty
1 78170-00 Regulator Assembly, Turbodisk 2 Drive Air (Includes the Following:) 1
SSP-6439 Elbow, 1/4 O.D. Tube x 1/4 NPT Male Swivel 2
SSV-8221 Regulator, 1/2 NPT Ported, Air Piloted 1
7819-16 Nipple, 1/2 NPT x 1.5 Long, Brass Pipe 1
LS0147 Regulator, 1" Ported, Manual Adj. Air, 0-125 psi, 250 CFM 1
7596-12 Bushing, 1" NPT x 1/2 NPT, Brass 1
GA-316 Gauge, 0-160 psig, 1/4 NPT, Air 1
41-FP-1021 Nipple, 1" NPT x 3/4 NPT, Hex Reducing 1
HAF-503 Air Filter, 3/4 NPT 1
2 78166-00 Hose Assembly, Compressed Air (Includes the Following:) 1
78164-00 Hose, 3/4" I.D., Push-Loc Air 5 ft.
78165-00 Fitting, Female SAE 45o Swivel x 3/4" I.D. Hose 2
3 20222-00 Air Heater Assembly 1
4 78176-01 Tubing, 1/2" O.D. x .375" I.D., Green Nylon To Suit
5 SSM-5805 Air Filter, 1/4 NPT 1
LN-9240-02.1
13
Turbodisk 2 - Installation
14
Figure 3a: Upper Turbodisk 2 Bulkhead Plate (Reference Figure 26)
LN-9240-02.1
TURBODISK 2 SIGNAL/PORT IDENTIFICATION TABLE
(Figure 3b)
Turbodisk 2 - Installation
Designation as Marked
on Bulkhead
F.O
HV
P1D
P1DL
R1H
R1L
P1S
P1R
P1T
P2D
P2DL
R2H
R2L
P2S
P2R
Fiber Optic Cable
High Voltage Cable
Paint #1 Dump
Paint #1 Dump Line
Regulator #1 High
Regulator #1 Low
Paint #1 Supply Line
Paint #1 Return Line
Paint #1 Trigger
Paint #2 Dump
Paint #2 Dump Line
Regulator #2 High
Regulator #2 Low
Paint #2 Supply Line
Paint #2 Return Line
Description
Tubing Color
Natural
Natural
Red
Natural
Orange
Yellow
Natural
Natural
Green
Black
Natural
Silver
Blue
Natural
Natural
P2T
S1.IN
S2.IN
T.A1
T.A2
Paint #2 Trigger
Solvent #1 Supply
Solvent #2 Supply
Turbine Air #1
Turbine Air #2
Figure 3b: Turbodisk 2 Signal/Port Identication Table
Natural
Natural
Natural
Green
Green
LN-9240-02.1
15
Turbodisk 2 - Operation
OPERATION
!
C A U T I O N
> Fluids and lubricants used in this system
must contain NO silicones!
> Do NOT operate the unit without an atomizer
disk! Without a disk, overspeed, resulting in
premature bearing failure, is possible.
> The air supplied to the motor must be dry,
clean and free of oil or moisture. The atmospheric
dew point should be 10oF or less. The air heater
used should be adjusted only high enough to
prevent condensation from forming on the motor
housing or at the exhaust port.
W A R N I N G
!
> Operators must be fully trained in safe
operation of electrostatic equipment. Operators
must read all instructions and safety precautions
prior to using this equipment (See NFPA 33,
Chapter 16).
As with any spray nishing system, operation of the
Turbodisk 2 involves properly setting the operating
parameters to obtain the best nish quality for the
coating material being sprayed, while maintaining
correct operation and reliability of the equipment
used. Adjustments to operating parameters,
which cover spraying, cleaning and on/o control,
include:
• Fluid Type
• Fluid Flow Rate
• Turbine Speed
• Electrostatic Voltage
• Target Distance
COATING MATERIALS
The Turbodisk 2 can be used with a broad range
of coating material conductivities. However, with
waterborne paints, it may be necessary to isolate the
paint supply from ground.
W A R N I N G
!
> Isolated uid supplies using either waterborne
or highly conductive solvent base coatings can
produce hazardous high voltage discharges
which can cause res or injury to personnel.
FLUID FLOW CONTROL
-REFER TO FIGURES 19-22
Fluid flow control is dependent on the valve
conguration of the Turbodisk 2. If the Turbodisk 2
is congured with no valves or a 3-way valve, uid
ow is controlled externally at the paint source. If the
Turbodisk 2 is equipped with a regulator, uid ow
can be controlled via the air pilot signal. The high
ow and low ow regulators each have procedures
on how to control and deliver consistent uid ows.
For more information on controlling the uid delivery
using regulators, refer to that specic manual which
is included with the system.
To check uid ow rates, the disk must be removed.
See the maintenance section for removal procedure.
The uid can then be manually triggered to measure
actual ow in a graduated beaker over a specied
time period.
W A R N I N G
!
> Danger of shock and/or personal injury can
occur. Proper grounding procedures, which are
outlined in the Ransburg safety bulletins, must
be followed. Personnel must never work near or
perform work on the turbine when the turbine
is spinning or when high voltage is on.
16
LN-9240-02.1
FLUID VALVE CONTROL
Trigger and Dump
-REFER TO FIGURES 4 & 25
Turbodisk 2 - Operation
The uid valves in the Turbodisk 2 are actuated by an
air signal. The air pressure must exceed 70 psi to assure
proper actuation of the valve. Applying air to the valve
actuator turns on the uid ow for that valve.
The trigger valve controls the paint ow to the disk.
When actuated, paint ows through the valve to
the uid tube. The disk should be spinning at a RPM
speed that is fast enough, (that when uid is turned
on) to enable the uid to ow through the disk paint
passage holes and be atomized.
The dump valve controls the paint ow through the
dump line. When actuated, paint ow is directed to the
dump return line. This provides a method of rapidly
removing paint from the incoming line for cleaning
and/or color change. Normally, the dump valve is not
actuated at the same time as the paint trigger valve
since the trigger valve is intended to cause the uid
ow to the disk at the prescribed input pressure.
FLUID & AIR PRESSURE
REQUIREMENTS
-REFER TO FIGURE 4
Fluid and air pressure requirements are dependent
on the uid trigger valve conguration.
No Valves
78718-01 thru -10
Air Pilot Fluid
Regulator
Air Inlet Trig/
Dump Valve
Fluid Inlet
Pressure
Solvent Inlet
Note: Trigger/dump valves (CCV-403-SS) are rated to 300 psi maximum inlet uid pressure but are
limited to the lower pressure limit of the uid regulators.
------------------
------------------
------------------
------------------
Figure 4: Turbodisk 2 Fluid & Air Pressure Requirements
3-Way ON/OFF
(18283)
78718-11 thru -20
------------------
120 psi max.
300 psi max.
30-60 psi max.
Trigger/Dump
w/High Flow
(70171-04)
Regulator
78718-21 thru -30
100 psi max.
70-100 psi
80-100 psi max.
30-60 psi max.
Trigger/Dump
w/Low Flow
DR-1 (74151)
Regulator
78718-31 thru -xx
100 psi
70-100 psi
80-100 psi max.
30-60 psi max.
LN-9240-02.1
17
Turbodisk 2 - Operation
TURBINE SPEED
Turbine speed is determined by the drive air pressure
at the rotary atomizer and uid ow rate.
Turbine speed can be closed loop controlled using
the ber optic speed transmitter mounted at the back
of the turbine rotator assembly as a speed input to
remote speed controls such as the PulseTrack.
NOTE
> The disk rotational speed determines
the quality of atomization and can be varied
for dierent ow rates and viscosities. For
optimum transfer eciency and spray pattern
control, the disk rotational speed should be
set at the minimum required speed to achieve
proper atomization. Excessive speed reduces
transfer eciency!
W A R N I N G
!
> Do not exceed the maximum rated speed of
40,000 RPM for the 6 inch conical disk and 27,000
RPM for the 6 inch uni-disk.
Atomizers
-REFER TO FIGURE 5
W A R N I N G
!
> Never operate any disk atomizer in excess of
it's maximum rated speed ("K" number) as listed
in the service manual. Excessive speed may cause
the disk to disintegrate, causing serious damage
and/or injury.
All atomizers manufactured after April 6, 1982, bear
a “K” number. That number indicates the maximum
safe rotation speed for that series in tens of thousands.
For example:
9K = 9,000 RPM maximum safe speed,
40K = 40,000 RPM, etc.
If you have an atomizer that does not have a “K”
number, contact your Ransburg representative for
its maximum safe operating speed.
TYPICAL MAXIMUM SAFE OPERATING SPEEDS
Atomizer Disk
6" Uni-Disk
8" Uni-Disk
10" Uni-Disk
12" Uni-Disk
6" Conical
9" Conical
12" Conical
Figure 5: Typical Maximum Safe Operating Speeds
18
Part Number
19830-06
19830-08
19830-10
19830-12
20485-62
20485-92
20485-12x
Max. RPM
27,000
23,000
15,000
15,000
40,000
25,000
20,000
LN-9240-02.1
Turbodisk 2 - Operation
ELECTROSTATIC VOLTAGE
In the system, the high voltage is supplied to the
Turbodisk 2 by either the MicroPak Industrial power
supply system or Voltage Master series power
supplies.
The MicroPak Indus trial power supply uses
proven high voltage generator technology that
is microprocessor controlled for diagnostics and
communication. The controller is packaged in
standard rack mounted Eurocard format for easy
access and system integration.
The Voltage Master power supplies are general
purpose heavy duty power supplies with years of
proven reliability. They have variable voltage control,
many safety features, and remote analog voltage
control capabilities.
NOTES:
TARGET DISTANCE
The distance between the Turbodisk 2 and the target
will aect the nish quality, penetration and eciency.
Closer distances give wetter nishes and greater
eciency, while greater distances give drier nishes.
The recommended normal disk edge to target range
is 12 inches minimum for optimum performance.
LN-9240-02.1
19
Turbodisk 2 - Maintenance
MAINTENANCE
GENERAL
Verify daily that the operating parameters have
not varied dramatically. A sudden change or even
a gradual decay in performance could be early
indications of component failure.
No rmal ma intenance procedures should be
established and recorded at the initial start-up. All
maintenance schedules are subject to variation
based on use. Periodically review these maintenance
schedules as equipment ages and needs change.
CLEANING PROCEDURES
W A R N I N G
!
> Electrical shock and re hazards can exist
during maintenance. The power supply must be
turned o before entering the spray area. Spray
booth fans should remain on while cleaning
with solvents.
> Never touch the disk atomizer while it is
spinning. The edge of the disk can easily cut into
human skin, gloves or other materials. Be sure the
disk atomizer has completely stopped spinning
before attempting to touch it. Approximate time
for the disk to stop spinning after turning o the
drive air is about three minutes.
!
> Do not immerse the Turbodisk 2 assembly
in solvent or other liquids. Turbine components
will be damaged.
> Do not soak the disk in solvent longer than
24 hours.
C A U T I O N
Internal Fluid Path Cleaning
With the high voltage turned o and the disk spinning,
ush cleaning solvent through the incoming paint
line or through the solvent inlet line. If it is desired to
clean just the face of the disk o, ush solvent through
the solvent inlet. If a color change is required, ush
the entire system. The spinning disk will atomize the
solvent and clean out the disk passages. If equipped,
trigger the dump valve to catch the wasted paint from
the incoming line, then ush the disk with solvent
after closing the dump valve.
NOTE
> Solvent ushing of the system (except
during color change) should be done with
the disk dismounted and with waste solvent
collected in a grounded container.
In addition to the above Warning, which relates to
potential safety hazards, the following information
must be observed to prevent damage to the
equipment.
20
LN-9240-02.1
Turbodisk 2 - Maintenance
External Atomizer Surface Cleaning
W A R N I N G
!
> To reduce the risk of re or explosion,
OSHA and NFPA 33 require that solvents used
for exterior cleaning, including disk cleaning
and soaking, be nonammable (ash points
higher than 100oF/37.8oC). Since electrostatic
equipment is involved, these solvents should
also be nonpolar. Examples of nonammable,
nonpolar solvents for cleaning are: Amyl acetate,
methyl amyl acetate, high ash naphtha and
mineral spirits.
> Do not use conductive solvents such as MEK to
clean the external surfaces of the Turbodisk 2.
> Never lower the Turbodisk 2 assembly into a
drum for ushing or color changing.
Clean the disk by soaking in an appropriate solvent
to loosen paint residue. Do not soak for more than a
24 hour period. Use a soft cloth to remove the paint
from the surface and a soft bristle brush to remove
paint from the well area. The splash plate may need
to be removed to clean the paint well. The screws
must be retorqued to 24 lb•in after cleaning.
Reinstall the disk and torque the mounting nut to
50-60 lb•in.
W A R N I N G
!
> Do not attempt to clean the disk edge while
it is rotating. Do not attempt to slow down or
stop the disk by holding a rag or a gloved hand
against the edge. This could cause physical harm
and/or damage to the disk.
!
C A U T I O N
Disk Cleaning
Normally, the internal cleaning instructions will
suce to clean the disk. If ushing the disk does not
remove all the residue, the disk may be removed for
hand cleaning. Unscrew mounting nut and remove
the disk by using the supplied disk puller.
Inspection of the disk is required to determine if
wear to the serrated edge or damage has occurred.
Wear can cause a reduction in transfer eciency and
excessive paint wrap on the atomizer fairing.
NOTE
> The turbine shaft must be held with a
7/16” open end wrench while using the disk
puller.
W A R N I N G
!
> Do not use abrasive materials which will
scratch or damage the disk. Cleaning pads such
as Scotch-Brite® should not be used.
> Using an atomizer disk with paint buildup may
cause an imbalance. This may result in bearing
damage and turbine failure. This condition
may also stress the disk when operating at high
speeds.
> Before reinstalling the disk onto the shaft,
check and clean the tapered mating surface for
paint residue.
> Care must be taken when mounting the disk
assembly to the motor shaft. The mounting nut
should turn freely for several turns until it fully
bottoms on the disk assembly.
> Do not hold disk edge during removal. This
could result in injury.
LN-9240-02.1
21
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