Ransburg CCV-5100 User Manual
Ransburg
SERVICE MANUAL
LN-9113-06.3
(Replaces LN-9113-06.2)
March - 2013
COLOR VALVE STACK
MODEL: CCV-5100
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.)
Color Valve Stack - Safety
NOTE: This manual has been changed from revision LN-9113-06.2 to revision LN-9113-06.3.
Reasons for this change are noted under “Manual Change Summary” page 23 of
this manual.
Ransburg
LN-9113-06.3
Ransburg
Color Valve Stack - Contents
CONTENTS
SAFETY: 1-5
SAFETY PRECAUTIONS ......................................................................................................1
HAZARDS / SAFEGUARDS ..................................................................................................2-5
INTRODUCTION: 6-8
DESCRIPTION ......................................................................................................................6
SPECIFICATIONS .................................................................................................................6
COLOR STACK SELECTION CHART ..................................................................................7
PRE-ENGINEERED COLOR VALVE STACK ASSEMBLIES ................................................8
INSTALLATION: 9-10
INSTALLATION .....................................................................................................................9-10
PAGE
OPERATION: 11
OPERATION .......................................................................................................................... 11
MAINTENANCE: 12-14
MAINTENANCE ....................................................................................................................12-13
TROUBLESHOOTING GUIDE ..............................................................................................14
PARTS IDENTIFICATION: 15-21
COLOR VALVE STACK / PARTS LIST ................................................................................. 15-16
COLOR VALVE STACK ASSEMBLY MODEL IDENTIFICATION ......................................... 17
TABLE A - NUMBER OF COLOR VALVES .......................................................................... 18
TABLE B - AIR PUSH VALVES ............................................................................................. 19
TABLE C - CHECK VALVE OPTIONS .................................................................................. 19
TABLE D - FLUID INLET FITTINGS ..................................................................................... 19
CCV-403-SS CUTAWAY / PARTS LIST ................................................................................ 20-21
ACCESSORIES .................................................................................................................... 21
WARRANTY POLICIES: 22
LIMITED WARRANTY ...........................................................................................................22
LN-9113-06.3
Color Valve Stack - 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 Secon in this manual and the Ransburg
safety literature therein idened.
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 operang 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, LATEST EDITION, prior to installing,
operang, 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 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.
The hazards shown on the following pages
may occur during the normal use of this equipment. Please read the hazard chart beginning on
page 2.
1
LN-9113-06.3
Ransburg
Color Valve Stack - 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.
LN-9113-06.3
2
Color Valve Stack - 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
LN-9113-06.3
Ransburg
Color Valve Stack - 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.
LN-9113-06.3
4
Color Valve Stack - 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
LN-9113-06.3
Ransburg
INTRODUCTION
Color Valve Stack - Introductions
DESCRIPTION
CCV-5100 Color Valve Stack
The CCV-5100 Color Valve Stack is a manually
controlled pneumatic color change valve assembly. The stack allows for up to and including 30
different colors. Color changes are made using
CCV-403-SS color change valves.
CCV-403-SS Color Valve Stack
The CCV-403-SS Color Valve Stack is a pneu-
matically operated uid valve designed for use in
paint spray application systems. The valve can be
used in a variety of other applications. The valve
can be used separately for on/off control of paint
to a spray atomizer; or, as part of a multi-color
manifold assembly where colors can be quickly
ushed and changed when a color change is desired. The CCV-403-SS includes a red indicator
(visible through holes in the valve body) that can
be seen when the valve is turned “on.”
All parts that come in contact with the uid material
are made of either stainless steel or that is impervious to most solvents. All other parts of the valve
are made of brass, stainless steel, nickel-plated
brass, or hard coated (anodized) aluminum. The
valve is constructed with a smooth, unobstructed
uid path that allows for faster ush cleaning, and
also less pressure restriction. The valve body
has two uid inlet ports that allow uid to circulate
through the valve on a continuous basis. A plug
is provided when this feature is not to be used.
The double inlet ports also allow two valves to be
used as a uid on/off control and dump system.
SPECIFICATIONS
Environmental/Physical
Nominal
Dimensions: See “Color Valve Stack
Figure” in the “Parts
Identication” section.
Mechanical
Air Requirements:
Operating Pressure
Air Inlet/Outlet
Connections: 1/4-inch OD Tubing
Fluid Pressure: 300 psig (20.6 bar)
maximum
Fluid Inlet:
(Fitting installed 3/8 inch OD tubing)
Fluid Outlet:
(Fitting installed 3/8 inch OD tubing)
Fluid Flow Capacity:
pressure drop (Paint
viscosity @ 700
entipoise)Varies
according to material
pressure and viscosity.
Valve Actuation
Speed, On-Off Cyle: 55 cycles/min
70-100 psig (4.8-6.9 bar)
1/4-inch NPT(F) X 2
1/4-inch NPT(F) X 1 port
3800 cc/min @ 47 psi
port
LN-9113-06.3
Colors: Up to and including 30 colors total.
* If CCV valve is used for “Air Push” air leakage
may occur if pressure is excessive.
6
Loading...