Ransburg CCV-6100 User Manual
Ransburg
COLOR SELECT SYSTEM™
SERVICE MANUAL
CS-95-01.2
(Replaces CS-95-01.1)
March 2013
MODEL: CCV-6100
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
Ransburg
Color Select System - Contents
CONTENTS
PAGE
SAFETY: 1-4
SAFETY PRECAUTIONS ......................................................................................................1
HAZARDS / SAFEGUARDS ..................................................................................................2-4
INTRODUCTION: 5-13
DESCRIPTION ......................................................................................................................5
SPECIFICATIONS .................................................................................................................6
COLOR SELECT SYSTEM MODEL IDENTIFICATION ........................................................7-8
TYPICAL COLOR CHANGE STACK ......................................................................................9
COLOR SELECT BOXES ......................................................................................................10
CCV-403-SS CUTAWAY / PARTS LIST ..................................................................................11-13
INSTALLATION: 14-16
CONNECTIONS ....................................................................................................................14
TYPICAL COLOR SELECTSYSTEM INSTALLATION ..........................................................15
INSTALLATION DIAGRAM .....................................................................................................16
OPERATION: 17
OVERVIEW ...........................................................................................................................17
MAINTENANCE: 18-21
COLOR CHANGE VALVES ...................................................................................................18-19
TROUBLESHOOTING ..........................................................................................................20
COLOR SELECT BOX MOUNTING PATTERN ....................................................................21
WARRANTY POLICIES: 22
LIMITED WARRANTY ...........................................................................................................22
CS-95-01.2
Color Select System - 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.
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.
W A R N I N G
!
> The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
> This manual MUST be read and thor-
oughly understood by ALL personnel who
operate, clean or maintain this equipment!
Special care should be taken to ensure that
the WARNINGS and safety requirements
for operating and servicing the equipment
are followed. The user should be aware of
and adhere to ALL local building and re
codes and ordinances as well as NFPA-33
SAFETY STANDARD, 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 equip-
ment and process, resulting in more efcient
operation, longer trouble-free service and faster,
easier troubleshooting. If you do not have the
manuals and safety literature for your Ransburg
system, contact your local Ransburg representative or Ransburg.
1
CS-95-01.2
Ransburg
Color Select System - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate operation and maintenance pro-
cedures 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 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 (37.8oC).
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 ammable 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 modications may cause re or injury.
If used, the key switch bypass is intended for use
only during set-up 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.
CS-95-01.2
2
Color Select System - Safety
Ransburg
AREA
Tells where hazards
may occur.
General Use and
Maintenance
Electrical
Equipment
HAZARD
Tells what the hazard is.
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 ammable or combustible materials
may occur. Personnel are ex-
posed 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.
SAFEGUARDS
Tells how to avoid the hazard.
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, re 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 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.
Explosion Hazard/
Incompatible
Materials
3
An electrical arc can ignite coat-
ing materials and cause a re
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 equip-
ment 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.
CS-95-01.2
Ransburg
Color Select System - Safety
AREA
Tells where hazards
may occur.
Toxic Substances
HAZARD
Tells what the hazard is.
Certain material may be harmful
if inhaled, or if there is contact
with the skin.
SAFEGUARDS
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 sprayed and its
concentration. Equipment must be as prescribed
by an industrial hygienist or safety expert, and be
NIOSH approved.
CS-95-01.2
4
Color Select System - Introduction
INTRODUCTION
Ransburg
DESCRIPTION
Color Select System
The CCV-6100 Color Select System is a manually controlled pneumatic color change system.
The system consists of one or two color change
boxes, a Color Change Valve Stack, and 1/4 inch
OD poly tubing. The system allows for up to and
including (15) different colors. Color changes are
made using CCV-403-SS color change valves.
Valve
The CCV-403-SS is a pneumatically 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.
Main Box
The main box consists of two six-position pneumatic switches. The top switch switches between
off, air solvent and color. The color select position activates the bottom color switch and the
secondary box (if more than ve colors are to be
used). The bottom switch is used to select colors
1 through 5. All internal plumbing is 5/32 nylon
tubing. The external bulkhead ttings are for 1/4
inch O.D. tubing, including the supply air tting.
When High Voltage is on, both Solvent Flush
and Air Push are locked out so they cannot be
triggered.
Secondary Box
The secondary box also consists of two six position pneumatic switches. The top switch selects
color 6 through 10, the bottom 11 through 15. All
internal and external tubing connections are the
same sizes as the main box.
All parts that come in contact with the uid mate-
rial are made of either stainless steel or PTFE
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.
NOTE
> When using the secondary box, all color
select switches not in use must be set in
the OFF position.
5
CS-95-01.2
Ransburg
Color Select System - Introduction
SPECIFICATIONS
Air Requirements: 70-100 psig(4.8-6.9 bar)
Operating Pressure
Air Inlet / Outlet
Connections: 1/4” OD Tubing
Fluid Pressure: 300 psig (20.6 bar) max.
Fluid Inlet: 1/4” NPT (F) X 2 ports
(Fittings installed
3/8” OD tubing)
Fluid Outlets: 1/4” NPT (F) (Fitting
installed a 3/8” OD
tubing)
Fluid Flow: 3800 cc/min @ 47 psi
pressure drop (Paint
viscosity @ 700
centipoise) Varies
according to material
pressure and viscosity.
NOTES
Valve Actuation Speed,
On-Off Cycle: 55 cycles/min
Colors: Up to and including 5
colors, main box only.
Up to and including 15
colors total.
CS-95-01.2
6
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