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.
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 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, LATEST EDITION, prior
to installing, operating, 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 pag-
es may occur during the normal use of this
equipment. Please read the hazard chart beginning on page 2.
1
LN-9801-05.1
Ransburg
Electric Overhead Reciprocator - 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-9801-05.1
2
Electric Overhead Reciprocator - 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-9801-05.1
Ransburg
Electric Overhead Reciprocator - 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-9801-05.1
4
Electric Overhead Reciprocator - 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 occur. 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 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.
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-9801-05.1
Ransburg
INTRODUCTION
Electric Overhead Reciprocator - Introduction
GENERAL DESCRIPTION
Our new generation Electric TurboDisk Reciprocator presents the ideal alternative to hydraulic
reciprocators particularly for applications that
demand critical regulation in blended pattern
applications. This machine can be congured to
deliver stroke lengths from 5 ft. (1.524m) to 32 ft.
(9.7536m) in one foot increments and provides for
multiple points of hesitation throughout the stroke
length. It performs at a machine speed of 60
inches per second and can be interfaced with PLC
technology. The Electric TurboDisk Reciprocator
is easy to service and is the ideal replacement
machine for existing hydraulic systems.
FEATURES AND
BENEFITS
• No hydraulic power supply
Eliminates potential for paint nish contami nation. Also eliminates oil leaks, routine lter /
valve / seal maintenance requirements as well
as hoses or the possibility of leaky connections.
• Smooth operation
Delivers improved control over paint lm depo-
sition while extending equipment life.
• Easy installation
Compact and lighter weight with no hydraulic
tubing to run and install. Does not require oil
ll / ush procedure and eliminates start-up
issues due to contaminated control valves.
• Reduce maintenance costs
Elimination of hydraulic power greatly reduces
operational and maintenance costs.
• Elimination of slide bar adjustments.
• Elimination slide bar and aircraft cable
wear.
• User-friendly, easy to program.
• Counter balanced drive tube
Provides energy efcient, smooth operation with
enhanced acceleration / deceleration control.
• 4HP electric motor with vfd, closed-loop
control, heavy-duty triple chain drive
Delivers rugged, reliable performance with
accuracy to 1/4 inch. Stroke and velocity
adjust-
ments may be made “on the y” via enhanced
programmability - up to 10 programs - via
keypad with display.
• Fail-safe breaking
Provides added assurances that the drive tube
will lock in the event of a chain failure. Also, “run-
away” limit switches that will shut down and lock
the drive tube in the event of a controller failure.
LN-9801-05.1
6
Electric Overhead Reciprocator - Introduction
ELECTRIC VS HYDRAULIC DISC RECIPROCATOR
Electric FeaturesElectric Benets
Ransburg
1. No hydraulic power supply
2. Counter balanced drive tube
3. 4 hp electric motor with vfd, closed-loop control,
heavy duty triple chain drive
• No potential for paint nish contamination
• Less noise
• No oil leaks
• No environmental issues relative to oil
contamination
• No routine lter / valve / seal maintenance
• No hoses or leaky connections
• Less maintenance
• Less oor space
• Energy efcient
• Enhanced acceleration / deceleration control
• Smooth operation
• Rugged / reliable
• Enhanced programmability via keypad with
display
• 10 programs
• Acceleration / deceleration control
• Accuracy ± 1mm
• Stroke and velocity adjustment “on the y”
• Velocity to 5fps
• Zero back-lash
• Smooth, quiet operation
• Programmable hesitation up to 8 pts/program
• PLC option
4. Fail-safe breaking
5. Retrotable drive package to hydraulic machines
6. Smooth operation
7. Easier installation
8. Improved product availability
• Friction brake locks drive tube in position in event
of chain failure
• “Run-away” limit switches shut down and lock
drive tube in event of controller failure
• Boost option
• Auto I/D option
• Analog output option
• Upgrades for older hydraulic reciprocators
• Improved control over paint lm deposition
• Longer life
• Less oor space required
• No hosing / hydraulic tubing to run
• No oil ll / ush procedure
• No potential oil leaks
• No start-up issues due to contaminated control
valves, etc.
• No special order hydraulic cylinders
• All drive systems identical
7
LN-9801-05.1
Ransburg
Electric Overhead Reciprocator - Introduction
SPECIFICATIONS
Electrical Requirements
Power Required: 460 V 60Hz 3ø
Fuse: 15 amp
Motor Size: 4 hp
Dimensions: Varies with stroke length
Stroke Length: 5-32 ft.
(in one foot increments)
1.524-9.7536m
(in .3048m increments)
Machine Speed: 60-inches/second
152.4 cm/second
NOTES
LN-9801-05.1
8
Electric Overhead Reciprocator - Installation
INSTALLATION
Ransburg
READ BEFORE
INSTALLING
RECIPROCATOR
Prior to the reciprocator being lifted into the
vertical position, or operated, the following
precautions must be taken or severe damage
could occur:
• The drive chain is tie-wrapped to the drive
sprocket for shipping. The 6-inch telescoping tube
is cabled at the bottom of the machine to the guide
rollers. The cable and tie-wraps must ONLY be
removed AFTER the machine is completely
installed in the vertical position and prior to
any attempt to run the machine. *Cable and
tie-wraps must be cut and removed. DO NOT
attempt to break the cable and tie-wraps by
jogging the machine.
• Be sure the chain is centered on the sprocket
and the tie-wraps are in place before the machine
is lifted out of its horizontal or shipping position.
NOTES
• The reciprocator drive must be inspected after
the machine is installed, and before attempting
to jog or run. Visually inspect to assure that:
the chain is centered on the sprocket and properly
engaged and free from the limit switch arms, the
encoder is connected, and all drive components
are secured...at this point the cable and tie-
wraps must be removed and discarded. Only
after this inspection should the reciprocator
by cycled.
• It is advised to jog the machine through the full
stroke prior to running a cycle. It is suggested
that one person is at the control panel and one is
at the motor house...each with communication
capability with each other.
9
LN-9801-05.1
Ransburg
Electric Overhead Reciprocator - Installation
LN-9801-05.1
Figure 1: System Field Wiring, Level 1
10
Electric Overhead Reciprocator - Installation
Ransburg
11
Figure 2: System Field Wiring, Level 2
LN-9801-05.1
Ransburg
OPERATION
Electric Overhead Reciprocator - Operation
MAIN MENU
The MAIN MENU screen is used to access all
other sub-menus. From the main menu, other
menus are accessed using the function keys. The
list of sub-menus may be viwed using the up and
down arrow keys. It is not, however, necessary
to have the required sub-menu in view to select
it. Throughout the entire menu structure, the F12
function key is used to return to the main menu.
RUN MODE
The menu for RUN MODE is selected from the
MAIN MENU using the F1 key. The selections
under Run Mode determine the type of Program
which will be run. A Program is a sequence of
points and associated velocities, digital outputs
(2), and analog outputs (1). A program may
have from two to eight points. Shown below is
a description of a program with four points. The
program is run by the reciprocator in the forward
direction (Point 1 to 2 to 3 to 4) at the velocity
specied at the start of a segment. The digital
and analog outputs are also set as specied at
the starting point of the segment. At the last point
the sequence is reversed. The program is run in
the reverse direction (Point 4 to 3 to 2 to 1). In
order to maintain the same velocity, and digital
and analog outputs, while running in the reverse
direction, the values from the end point of each
segment must be used for that segment.
Point 1: 7” @ 30”/sec Dig1:0 Dig2:0 Analog: 0
Point 2: 35” @ 15”/sec Dig1:1 Dig2:0 Analog: 60
Point 3: 50” @ 30”/sec Dig1:1 Dig2:0 Analog: 0
Point 4: 97” @ 30”/sec Dig1:1 Dig2:0 Analog: 0
Point 5: 0”
LN-9801-05.1
12
Electric Overhead Reciprocator - Operation
Ransburg
NOTE
> The value of the velocity, digital outputs,
and analog output for the last point are
never used.
> The last point in a program is determined
by checking for the rst point which has a
zero entry for the position. For the program
depicted, the fth point must have a zero
entered for the position.
Although the program shown has the points or-
dered so that the rst point is at the top, with the
following points each increasing, this ordering is
not required. The points can be entered in any
way. The sequence can be such that the reciprocator reverses direction in the middle of the
sequence, the rst point in the sequence can be
at the bottom, and so on.
RUN SCREEN DATA
From the RUN MODE screen, the F2 function key
is used to select a special type of program. This
program, called a Manual Program, allows the
operator to quickly access the data for four points.
The data remains on the screen during operation,
and can be edited while running. This program
is useful if the opertor is typically adjusting the
top and bottom points, in order to maintain the
required coverage. The program does not start
until the START RECIPROCATOR push button,
under the display module, is pressed. To stop
the machine, the STOP RECIPROCATOR push
button is pushed.
HOME/PARK
From the main menu screen, the F2 function key
is used to access the homing and parking function.
RUN PROGRAM
From the RUN MODE screeen, the F1 function
key is used to select the program to run. Up
to ten programs are available, with up to eight
points per program. Once the program number
is entered, the status screen (F7) or main menu
screen (F12) may be selected. The program does
not start until the START RECIPROCATOR push
button, under the display module, is pressed. To
stop the machine, the STOP RECIPROCATOR
push button is pushed.
START HOMING
From the HOME / PARK screen, the F1 function
key is used to start homing the reciprocator. The
home position is at the top of the stroke. The
velocity of the machine while homing is selected
under machine setup (F5 from the main menu).
When the F1 key is pressed to start homing, the
status screen is immediately displayed. The status will be HOMING until the machine reaches
the top. The status will then change to HOMED.
All point data is referenced to the home position,
and the positive direction is down. This function
will normally not be used. If the machine has just
been powered up, and a program is started, the
machine will automatically go to home prior to
running the program.
13
LN-9801-05.1
Ransburg
Electric Overhead Reciprocator - Operation
PARK
From the HOME / PARK screen, the F2 function
key is used to start parking. The park position, as
well as the velocity of the machine while parking,
is dened by the user (see the “Machine Setup
Screen”, F5). This position is normally dened
near the bottom of the stroke, so that the disk
may be cleaned or repaired as required. When
the F2 key is pressed to start parking, the status
screen is immediately displayed. The status will
be PARKING until the machine reaches the pre-de-
ned park position. The status will then change
to PARKED. At this point, the motor power will
be off, the brake will be on, the digital and analog
outputs will be off, and the electrostatics will be off.
JOG MODE
The menu for Jog Mode is selected from the MAIN
MENU using the F3 function key. The jog mode
may be used for maintenance, when the machine
may need to be in a specic position. Also, if an
over travel limit switch is tripped, the jog mode is
required to move the machine off the limit switch
arm. The velocity of the machine in the jog mode
is selected under machine setup (F5 from the
main menu).
JOG UP/JOG DOWN
From the JOG MODE screen, the F1 function key
jogs the machine up, while the F2 function jogs
the machine down. The key must be held down in order to move the machine. If the key is
released, the motion immediately stops.
PROGRAM EDIT
Once the program number is selected, the F1
function key then starts the editing session. Each
program has available eight points, not all of which
may be required. Each point has an associated
position, velocity, two digital outputs, and two
analog outputs. The data points are accessed
using the F1 key to select the next point, and the
F2 key to select the previous point. The F3 key
is used to end the edit session.
NOTE
>Any of the 10 programs may be edited
while the machine is running. If the program
running is the same as the edited program,
any changes will take effect after completing
the editing, and when the program running
is a point number 1.
There are two modes for the data displayed on the
screen. In Page Mode, the arrow keys scroll up
and down through the data. In Data Entry Mode,
which is entered by pressing the F9 function key,
the currently displayed data elds may be modied
using the 0 to 9 keys to change the data. When the
F9 key is pressed, the rst data eld is highlighted
in reverse video. It may be modied at that time.
Pressing the F9 key again will cause the next
data on the screen to be highlighted. Thus, in
Data Entry Mode, all the data elds currently on
the screen may be modied, using the F9 key to
access the data elds. In order to return to Page
Mode, the Enter key must be pressed. Once
back in Page Mode, the up/down arrow keys may
be used to scroll to other data points for editing.
When the data has been changed as required,
the F3 key will exit the data edit mode and return
to the program select page for more editing, if
required. At this time, the F12 key will select the
main menu.
The menu for PROGRAM EDIT is selected from
the MAIN MENU using the F4 function key. The
program number to be edited, if different from the
desired value, needs to be entered prior to editing
of the values.
LN-9801-05.1
14
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