Ransburg A11925-00 User Manual
SERVICE MANUAL
LN-9256-07.4LN-9256-07.4
LN-9256-07.4
LN-9256-07.4LN-9256-07.4
(Replaces LN-9256-07.3)
July-2012
SERIALSERIAL
SERIAL
SERIALSERIAL
A A
TT
A
T
A A
TT
OMIZER MODULEOMIZER MODULE
OMIZER MODULE
OMIZER MODULEOMIZER MODULE
MODEL: A1MODEL: A1
MODEL: A1
MODEL: A1MODEL: A1
1925-001925-00
1925-00
1925-001925-00
IMPORIMPOR
IMPOR
IMPORIMPOR
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,
carefully read SAFETY PRECAUTIONS,carefully read SAFETY PRECAUTIONS,
starting on page 1, and all instructions in thisstarting on page 1, and all instructions in this
starting on page 1, and all instructions in this
starting on page 1, and all instructions in thisstarting on page 1, and all instructions in this
manual. Keep this Service Manual for futuremanual. Keep this Service Manual for future
manual. Keep this Service Manual for future
manual. Keep this Service Manual for futuremanual. Keep this Service Manual for future
reference.reference.
reference.
reference.reference.
TT
ANTANT
T
ANT
TT
ANTANT
: Before using this equipment,: Before using this equipment,
: Before using this equipment,
: Before using this equipment,: Before using this equipment,
Service Manual Price:Service Manual Price:
Service Manual Price: €
Service Manual Price:Service Manual Price:
15.00 (Euro)15.00 (Euro)
15.00 (Euro)
15.00 (Euro)15.00 (Euro)
$20.00 (U.S.)$20.00 (U.S.)
$20.00 (U.S.)
$20.00 (U.S.)$20.00 (U.S.)
NOTE:NOTE:
NOTE: This service manual has been superceded from service manual number
NOTE:NOTE:
manual number
the back cover of this manual.
LN-9256-07.4LN-9256-07.4
LN-9256-07.4. Reasons for this change are noted under “Manual Change Summary” inside
LN-9256-07.4LN-9256-07.4
LN-9256-07.3 LN-9256-07.3
LN-9256-07.3 to service
LN-9256-07.3 LN-9256-07.3
LN-9256-07.4
CONTENTSCONTENTS
CONTENTS
CONTENTSCONTENTS
SAFETY:SAFETY:
SAFETY:
SAFETY:SAFETY:
Serial Atomizer Module - Contents
PAGEPAGE
PAGE
PAGEPAGE
1-61-6
1-6
1-61-6
SAFETY PRECAUTIONS..........................................................................................................
HAZARDS / SAFEGUARDS......................................................................................................
INTRODUCTION:INTRODUCTION:
INTRODUCTION:
INTRODUCTION:INTRODUCTION:
GENERAL DESCRIPTION........................................................................................................
SPECIFICATIONS......................................................................................................................
INSTALLATION:INSTALLATION:
INSTALLATION:
INSTALLATION:INSTALLATION:
LOCATION..................................................................................................................................
CONNECTIONS.........................................................................................................................
OPERATION:OPERATION:
OPERATION:
OPERATION:OPERATION:
SPEED CONTROL.....................................................................................................................
79128-00 SERIAL ATOMIZER SPEED SELECT .....................................................................
AUTOMATIC SHUTDOWN........................................................................................................
OTHER MODES.........................................................................................................................
SIGNAL I/O.................................................................................................................................
MOTHERBOARDS.....................................................................................................................
SPEED CONTROL SYSTEM.....................................................................................................
SIDE VIEW..................................................................................................................................
DIP SWITCH SETTINGS...........................................................................................................
1
2-5
77
7
77
7
7
88
8
88
8
8
9-159-15
9-15
9-159-15
9
10
11
11
11-12
13
14
14
15
MAINTENANCE:MAINTENANCE:
MAINTENANCE:
MAINTENANCE:MAINTENANCE:
SERIAL ATOMIZER MODULE...................................................................................................
STATUS CODE DISPLAY..........................................................................................................
TROUBLESHOOTING / TROUBLESHOOTING GUIDE CHART...........................................
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS IDENTIFICATION:
PARTS IDENTIFICATION:PARTS IDENTIFICATION:
PARTS LIST................................................................................................................................
POWER CONNECTIONS TO MOTHERBOARD TB1.............................................................
TRANSCEIVER CONNECTIONS TO MOTHERBOARD TB(X)..............................................
WARRANTY POLICIES:WARRANTY POLICIES:
WARRANTY POLICIES:
WARRANTY POLICIES:WARRANTY POLICIES:
LIMITED WARRANTY................................................................................................................
LN-9256-07.4
16-1816-18
16-18
16-1816-18
16
16
17-18
19-2019-20
19-20
19-2019-20
19
19
19-20
2121
21
2121
21
Serial Atomizer Module - Safety
SAFETY
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONS
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
W A R N I N GW A R N I N G
W A R N I N G
W A R N I N GW A R N I N G
!!
!
!!
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!A WARNING!
A WARNING!
A WARNING!A WARNING!
you to a situation that might cause seri-you to a situation that might cause seri-
you to a situation that might cause seri-
you to a situation that might cause seri-you to a situation that might cause serious injury if instructions are not followed.ous injury if instructions are not followed.
ous injury if instructions are not followed.
ous injury if instructions are not followed.ous injury if instructions are not followed.
A CAUTION! states information that tellsA CAUTION! states information that tells
A CAUTION! states information that tells
A CAUTION! states information that tellsA CAUTION! states information that tells
how to prevent damage to equipment orhow to prevent damage to equipment or
how to prevent damage to equipment or
how to prevent damage to equipment orhow to prevent damage to equipment or
how to avoid a situation that might causehow to avoid a situation that might cause
how to avoid a situation that might cause
how to avoid a situation that might causehow to avoid a situation that might cause
minor injury.minor injury.
minor injury.
minor injury.minor injury.
A NOTE is information relevant to theA NOTE is information relevant to the
A NOTE is information relevant to the
A NOTE is information relevant to theA NOTE is information relevant to the
procedure in progress.procedure in progress.
procedure in progress.
procedure in progress.procedure in progress.
While this manual lists standard specifications
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.
states information to alertstates information to alert
states information to alert
states information to alertstates information to alert
> The user
with the Safety Section in this manual and
the Ransburg safety literature therein
identified.
> This manual
oughly understood by
operate, clean or maintain this equipment!
Special care should be taken to ensure that
WARNINGSWARNINGS
the
WARNINGS and safety requirements
WARNINGSWARNINGS
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to
codes and ordinances as well as
33 SAFETY STANDARD, 33 SAFETY STANDARD,
33 SAFETY STANDARD, prior to
33 SAFETY STANDARD, 33 SAFETY STANDARD,
installing, operating, and/or servicing this
equipment.
MUSTMUST
MUST read and be familiar
MUSTMUST
MUSTMUST
MUST be read and thor-
MUSTMUST
ALLALL
ALL personnel who
ALLALL
ALLALL
ALL local building and fire
ALLALL
W A R N I N GW A R N I N G
W A R N I N G
W A R N I N GW A R N I N G
!!
!
!!
NFPA-NFPA-
NFPA-
NFPA-NFPA-
>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 efficient 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.
11
1
11
LN-9256-07.4
Serial Atomizer Module - Safety
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Spray AreaSpray Area
Spray Area
Spray AreaSpray Area
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate operation
and maintenance procedures will
cause a fire hazard.
Protection against inadvertent
arcing that is capable of causing
fire or explosion is lost if any safety
interlocks are disabled during
operation. Frequent power supply
shutdown indicates a problem in
the system requiring correction.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
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, flushing or maintenance.
When using solvents for cleaning:
Those used for equipment flushing should have flash
points equal to or higher than those of the coating
material.
Those used for general cleaning must have flash
points above 100
o
F (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In
addition, ventilation must be maintained during
cleaning operations using flammable or combustible
solvents.
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 modifications may cause fire 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 NFPA-33, NEC, and
OSHA requirements.
LN-9256-07.4
22
2
22
Serial Atomizer Module - Safety
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
General Use andGeneral Use and
General Use and
General Use andGeneral Use and
MaintenanceMaintenance
Maintenance
MaintenanceMaintenance
ElectricalElectrical
Electrical
ElectricalElectrical
EquipmentEquipment
Equipment
EquipmentEquipment
Improper operation or maintenance
may create a hazard.
Personnel must be properly trained
in the use of this equipment.
High voltage equipment is utilized. Arcing in areas of flammable or combustible materials
may occur. Personnel are exposed to high voltage during
operation and maintenance.
Protection against inadvertent
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.
Personnel must be given training in accordance with
the requirements of NFPA-33.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, fire protection, operation
maintenance, and housekeeping. Reference OSHA,
NFPA-33, and your insurance company requirements.
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-33.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of flammable 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.
ExplosionExplosion
Explosion
ExplosionExplosion
Hazard /Hazard /
Hazard /
Hazard /Hazard /
IncompatibleIncompatible
Incompatible
IncompatibleIncompatible
MaterialsMaterials
Materials
MaterialsMaterials
33
3
33
An electrical arc can ignite coating materials and cause a fire or
explosion.
Halogenated hydrocarbon solvents
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.
Before turning the high voltage on, make sure no
objects are within the sparking distance.
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, flushing, 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.
LN-9256-07.4
Serial Atomizer Module - Safety
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Toxic SubstancesToxic Substances
Toxic Substances
Toxic SubstancesToxic Substances
Spray Area /Spray Area /
Spray Area /
Spray Area /Spray Area /
High VoltageHigh Voltage
High Voltage
High VoltageHigh Voltage
EquipmentEquipment
Equipment
EquipmentEquipment
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Certain material may be harmful if
inhaled, or if there is contact with
the skin.
This is a high voltage device that
can produce electrical arcs capable
of igniting coating materials.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
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 spray-ed and its
concentration. Equipment must be as prescribed by
an industrial hygienist or safety expert, and be
NIOSH approved.
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.
(Reference NFPA-33)
A safe distance must be maintained between the
parts being coated and the atomizer bell. A distance
of at least 1-inch for each 10kV of power supply
output voltage is required at all times.
Personnel Safety/Personnel Safety/
Personnel Safety/
Personnel Safety/Personnel Safety/
MechanicalMechanical
Mechanical
MechanicalMechanical
HazardsHazards
Hazards
HazardsHazards
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 of clothing can also be
caught by the rotating bell.
Parts must be supported so that they will not swing
and reduce the clearance specified above.
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.
Unless specifically approved for use in hazardous
locations, the power supply and other electrical
equipment must not be used in Class I, Division 1 or
2 locations.
Personnel must stay clear of the bell whenever it is
rotating.
Before touching the bell, the turbine air must be shut
off.
If the disk has been rotating, allow at least three
minutes for it to come to a complete stop before
touching it.
LN-9256-07.4
44
4
44
Serial Atomizer Module - Safety
AREAAREA
AREA
AREAAREA
Tells where hazards
may occur.
Personnel SafetyPersonnel Safety
Personnel Safety
Personnel SafetyPersonnel Safety
Intended UseIntended Use
Intended Use
Intended UseIntended Use
HAZARDHAZARD
HAZARD
HAZARDHAZARD
Tells what the hazard is.
Skin puncturing by sharp electrode. Take precautions to see that flesh is not punctured by
Using coating materials and/or
cleaning and flushing solvents
which have flash points below 100oF
(37.8oC) may cause a fire hazard.
SAFEGUARDSSAFEGUARDS
SAFEGUARDS
SAFEGUARDSSAFEGUARDS
Tells how to avoid the hazard.
sharp electrode.
This system is intended for use with waterborne
coating formulations only. As stated in this manual,
this system can also be used for solventborne coatings.
55
5
55
LN-9256-07.4
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