Ransburg A12520-XXXX User Manual
GMS
Ground Monitoring System
Ransburg
PRODUCT MANUAL
LN-9265-09.2
MODEL: A12520-XXXX
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.
Product Manual Price: $50.00
LN-9265-09.2
1
NOTES
LN-9265-09.2
2
CONTENTS
Section 1: SAFETY
5
Safety Precautions
Hazards / Safeguards
Section 2: INTRODUCTION 10
FM Conguration
Inputs
Outputs
Other Considerations
Theory of Operation
Features and Benets
Specications (Environmental / Physical)
Selection Guide
Section 3: INSTALLATION 16
Mounting the Control Unit
I/O Connections
PLC Interface
AC Input Connections
Interlocks
Relay Contact Outputs
Low Voltage Cable
Section 4: OPERATION 21
Powering Up the Control Unit
Lockouts
Set-up
Calibration
Operation Sequence
Section 5: MAINTENANCE 27
Suitable Solvents for Cleaning GMS Probe
LN-9265-09.2
3
CONTENTS
Section 6: TROUBLESHOOTING 28
Fault Descriptions
Section 7: APPENDIX 31
Probe Tool Center Point Drawings
Recommended Spare Parts List
Conguration Drawing w/ Parts List
Control Unit Electrical Schematic
Control Unit Parts List
Probe Parts List
Mounting Congurations
Warranty Policies
LN-9265-09.2
4
Section 1: 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:
CAUTION - states information that tells
how to prevent damage to equipment or
how to avoid a situation that might cause
minor injury.
WARNING - states information to alert you
to a situation that might cause serious injury if instructions are not followed.
WARNING
• The user MUST read and be familiar with the Safety Section in this manual and the Rans-
burg safety literature therein identied.
While this manual lists standard specications and ser-
vice procedures, some minor deviations may be found
between the 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 equipment 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.
• 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,
2009 EDITION, prior to installing, operating, and/or servicing this equipment.
• The hazards shown on the following pages may occur during normal use of this equipment. Please
read the hazard chart beginning on page 6.
LN-9265-09.2
5
AREA HAZARD SAFEGUARDS
Spray Area Fire Hazard
Improper or inadequate operation and main-
tenance 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 shutdown
indicates a problem in the system requiring
correction.
Follow These Guidelines
Fire extinguishing equipment must be present in the
spray area and test 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 1000F (37.80C).
Spray booth ventilation must be kept at the rates
required by NFPA 33, 2009 Edition, OSHA and local
codes. Ventilation must be maintained during cleaning
operations using ammable or combustible solvents.
Electrostatic arcing must be prevented.
Non-factory replacement parts or unauthorized equip-
ment modications may cause re or injury.
If used, a key switch bypass is intended for use only
during setup operations. Production should never be
done with safety interlocks disabled.
Never use equipment for use in waterborne installations
to spray solvent based materials.
LN-9265-09.2
6
AREA HAZARD SAFEGUARDS
Spray Area Explosion
Improper or inadequate operation and
maintenance procedures may cause an
explosion.
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 shutdown
indicates a problem in the system requiring
correction.
Follow These Guidelines
Electrostatic arcing MUST be prevented.
All electrical equipment must be located outside Class
I or II, Division 1 or 2 hazardous areas, in accordance
with NFPA 33, 2009 Edition.
Test only in areas free of ammable or combustible
materials.
The current overload sensitivity (if equipped) MUST
be set as described in 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 shutdown indicates a problem with the
system which requires correction.
Always turn the control panel off prior to ushing, cleaning, or working on spray system equipment.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA 33, 2009 Edition.
Have re extinguishing equipment readily available and
tested periodically.
Spray Area Follow These Guidelines
Explosion - Incompatible Materials
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.
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.
LN-9265-09.2
7
AREA HAZARD SAFEGUARDS
Spray Area / High Volt-
age Equipment
Electrical Equipment Follow These Guidelines
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.
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.
Electrical Discharge
Electrical Discharge
Follow These Guidelines
Parts being sprayed must be supported on conveyors
or hangers and be grounded. The resistance between
the part and ground must not exceed 1 mega ohm.
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 I, Division 1 or
2 locations.
All electrical equipment must be located outside Class
I or II, Division 1 or 2 hazardous areas. Refer to NFPA
33, 2009 Edition.
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 coating materials
and cause a re or explosion.
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.
LN-9265-09.2
8
AREA HAZARD SAFEGUARDS
Toxic Substances Mechanical Hazard
Certain material may be harmful if inhaled,
or if there is contact with the skin.
Robot Work Area Mechanical Hazard
Improper use or maintenance can lead to
hazardous conditions, particularly from un-
expected robot manipulator movement.
Follow These Guidelines
Follow the requirements of the Material Safety Data
Sheet supplied by the coating 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.
Follow These Guidelines
Applicator adjustments or maintenance should be done
after the robot is taken out of service. Do not adjust or
repair the applicator if the robot is operating or standing
ready to start.
Refer to robot operating instructions for the procedures
to take a robot out of service.
Follow all OSHA Lockout / Tagout procedures when
performing any maintenance.
All Areas Follow These Guidelines
Improper / Inadequate Training
Improper operation or maintenance may
create a hazard.
Personnel must be properly trained in the
use of this equipment.
Personnel must be given training in accordance with
the requirements of NFPA 33, 2009 Edition.
Instructions and safety precautions must understood
prior to using this equipment.
Comply with appropriate codes governing ventilation,
re protection, operation maintenance, and housekeeping. OSHA references are sections 1910.94 and
1910.107. Also refer to NFPA 33, 2009 Edition and
your insurance company requirements.
LN-9265-09.2
9
Section 2: INTRODUCTION
The Ransburg Ground Monitoring System (GMS) monitors the ground condition of non-metallic parts and provides
feedback, increasing the margin of safety. After scanning the part with an electrostatic charge, the GMS’s control unit
circuitry monitors several variables and compares the reading against a pre-determined standard. If the reading falls
outside of an acceptable range, the notication alarm will activate, allowing adjustments or corrections to be made, eliminating rework while increasing quality. Improper grounding can cause overspray, excess paint build-up, thin lm build,
ruined parts or a safety hazard.
The GMS consists of:
• Control Unit
• Probe Detector
• Cable
• Machine Mount Bracket
The device can be used in the spray area, FM testing is successfully complete and approval pending.
The control unit consists of an electrostatic generator, input-output signal circuitry, and is microprocessor/software based.
The probe detector contains a high voltage cascade, electrode assembly and an electrical circuit capable of providing
feedback to the control unit.
Probe Detector
Control Unit
LN-9265-09.2
10
FM CONFIGURATION
This device is FM approved when congured per the drawing shown below .
LN-9265-09.2
11
INPUTS
• 110 or 220VAC Main power input
• The control unit requires an input signal for part detection. A limit switch, photo-eye, PLC or robot signal input is
acceptable.
• The device will require eld calibration to the specic application.
OUTPUTS
• The control unit will provide a visual signal to alert the end user of the detection of an ungrounded part.
• Two contact closures (UNGROUNDED & HV ON) are provided to signal the application of HV and the detection of
an ungrounded part.
• These contacts may be hooked to a PLC, horn, or light (shown in the PLC INTERFACE section of this manual).
OTHER CONSIDERATIONS
• Designed for use on non-metallic substrates only.
• Accuracy of the system is dependent on part to probe detector distance staying consistent.
• The probe to part distance should be set to 4 inches and should not vary more than ± one (1) inch.
• Probe detector must stay clean.
• Inspect the probe detector electrode every two weeks.
LN-9265-09.2
12
THEORY OF OPERATION
• The part(s) to be detected are subjected to a high voltage electrostatic charge.
• The control unit circuitry measures the amount of energy required to charge the part during the charging time select-
ed, and compares that value with an installation specic pre-set “window”.
• If the reading falls within the end user determined pre-set setpoint, the part passes the ground test.
FEATURES AND BENEFITS
• Complete Monitoring System...consists of a control unit, ground probe, mounting bracket and low voltage cable.
• Meets Stringent Safety Requirements...FM approved for use in Class 1, Division 1 painting environments.
• Utilizes Various Input Signals for Part Detection...limit switch, photo-eye, PLC, robot signal or any 0 Volt ground
trigger detection process.
• Advanced Technology...allows user to adjust control unit for specic eld calibration..
• User-Friendly Control Unit Software...allows end user to control start timer, scan duration timer and alarm outputs.
• Easy to Read Visual Indicators...users receive simple, precise feedback regarding ground path strength.
• Versatile Model...compatible with electrostatic systems, plastic or other non-metallic surfaces.
• Versatile Ungrounded Part Alert Notication...unit provides two contact closures that may be interfaced to a PLC,
horn or light for ungrounded part alert. Contact closures included are:
1. One FAULT indicator
2. One HIGH VOLTAGE ON indicator
LN-9265-09.2
13
OPERATIONS:
• Probe distance from substrate for accurate monitoring: 4 inches +/- one inch
(100 mm +/- 25 mm)
• Minimum time for measurement and result output signal: 3.5 seconds
• Low voltage cable length: 10 meters standard
15, 20, 25 & 30 meters optional
CONTROL UNIT:
• Input voltage: 110/220 VAC
• Probe output: 85 kV maximum
• Current output: 100 µA maximum
• Height:: 5.5 inches (14.0 cm)
• Width: 8.5 inches (21.6 cm)
• Depth: 7.5 inches (19.1 cm)
SPECIFICATIONS - Environmental / Physical
PROBE:
• Weight: 7.5 lbs. (3.4 kg)
• Length: 12.1 inches (30.7 cm)
• Weight: 1 lb 10 oz (.75 kg)
• Mounting bracket weight: 1 lb 3 oz (.65 kg)
• Mounting bracket adjustment angles: 0, 30, 60 & 90°
LN-9265-09.2
14
Loading...