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1. a da 2 Semar Pad Single Sensor P amp F Barriers Hazardous Area ore Serea Pinak Single Sensor Stahl Barriers Hazardous Area A13256 01 Sensor Sensor Pinot Fim JS OC Soures block Pn J1 GNO q ren Fin 4 Sigo Out green dron Single Sensor Turck Barriers FM 14 01 Non Hazardous Area 24 VDC Power Supply Cable must be sealed off at booth wall according to local electrical code requirements A13632 00 P8F Option 77220 or similar GND cable assembly No Grounded DIN Rail 24 VDC Power Supply o e A13632 00 Stahl Option Cable must be sealed off at booth wall according to local electrical code requirements 77220 or similar cable assembly Fim JS OC Soures block A13256 01 a Sensor Pin 41 GNO Cred A Fin Ja See Cut graon Cable must be sealed off at booth wall according to local electrical code requirements SL Sqn R i xo Grounded DIN Rail Non Hazardous Area 24 VDC Power Supply e a A13632 00 Turck Option lt GNO 77220 or similar bl a sembl y TN LR Grounded Terminal Block Y Grounded DIN Rail Signo to Sha Controller Sa Wove 59 Wove Signal Lo Controller Sq Wove Signol ta Controll2. 01 02 Flowmeter Cable Assembly incl connectors A13159 01 02 only Fiber Optic Cable Assembly A13159 03 only Sensor Forward Sensing Only Sensor Bi directional forward and reverse sensing Fiber Optic Transmitter Forward Sensing Only i l SHCS S S M6x30mm Upper Housing Hexagon Flowmeter Shaft Flowmeter A12715 00 Gear Flowmeter Std Gear Special Tin Coated Optional 10 Gasket Hexagon Flowmeter Lower Housing Hexagon Flowmeter E NOTE The flowmeters are shipped from the factory with white PTFE O rings Replacement O rings will be tinted blue to indicate that they are metric for use in the A13159 A12712 and A12713 flowmeters 13 FM 14 01 WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipment that falls within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with Ransburg s written safety and operating instructions and has been used under normal operating conditions Normal wear items are excluded THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOID ALL WARRAN TIES SPARE PARTS One hundred and eighty 180 days from date of purchase except for rebuilt parts any part number ending in R for which the warranty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 yea
3. ELECTRICAL NOISE All flowmeter cable assemblies employed in all Binks and Ransburg products use shielded twisted pair cable and are there fore designed to minimize noise interfer ence with the flowmeter signals These cables cannot however eliminate all spurious noise signals A WARNING gt It is important during installation to in sure that the flowmeter cables are not run near within 12 noise generating devices such as large electric motors fluorescent lighting transformers ballasts etc SINGLE vs DUAL SENSOR INSTALLATIONS When single sensor flowmeters are used reverse flow detection is not possible When employing single sensor flowmeters on products such as Ransburg s DynaFlow System or RansFlow System it is neces sary to jumper the unused gate signal inputs to the 24 VDC supply Refer to the user s manual for the specific system the flowmeter is being installed on for complete details on how and where to add these jumpers Note The fiberoptic version of this flowmeter is a single sensor meter gt This meter may be installed in Class Division Group D locations when used in conjunction with the proper Zener Barriers Refer to pages 10 and 11 for complete connection details A13159 Flowmeter Operation OPERATION PRINCIPLE OF OPERATION Gear type flowmeters work on the principle that a small volume of material is trapped between each set of gear teeth and as the gears ro
4. the lubrication the flowmeter gears require Lubrication is normally provided by the metered fluid or solvent 2 Air purges can cause some coating materials to dry on the flowmeter shafts and gears thus affecting the performance characteristics of the flowmeter especially when water based materials are used 3 Excessively long air purges will cause premature gear and shaft failure 4 All clean cycles should begin with a solvent push to prevent drying of coating material on flowmeter parts 5 Solvent and air chop cycles are recom mended as the most efficient way of flushing flowmeters 6 On plural component materials or other materials that cause a skinning effect on the inside of the fluid lines it is recom mended that the fluid lines be left filled with non pressurized solvent during idle times The system should then be flushed prior to loading for the next spray cycle 7 Air purges are not recommended in water based applications FM 14 01 A13159 Flowmeter Operation INTRINSICALLY SAFE OPERATION In order to operate the flowmeter in hazardous areas Class I Division Group D locations it is necessary to run the power going out to the flowmeter and the signal or signals returning from the flowmeter sensor through the approved zener barrier Hazardous Area Fin 45 0C Source pluck A13256 01 Sensor Fin d1 6N0 a Lezo Fin J4 Signal Qut green area
5. with safety interlocks disabled Never use equipment intended for use in water borne installations to spray solvent based materi als The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC OSHA local country and European Health and Safety Norms A13159 Flowmeter Safety AREA Tells where haz ards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate opera tion and maintenance proce dures 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 or Con troller shutdown indicates a problem in the system requiring correction Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment 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 re quired at all times Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or Il Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable or combus tible m
6. 4 01 A13159 Flowmeter Safety SAFETY 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 infor mation relates to USER SAFETY and PRE VENTING EQUIPMENT PROBLEMS To help you recognize this information we use the fol lowing symbols Please pay particular attention to these sections A WARNING states information to alert you to a situation that might cause serious inju ry 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 pro cedure in progress While this manual lists standard specifications and service procedures some minor devia tions may be found between this literature and your equipment Differences in local codes and plant requirements material delivery require ments etc make such variations inevitable Compare this manual with your system instal lation drawings and appropriate Ransburg equipment manuals to reconcile such differ ences Careful study and continued use of this manual will provide a better understanding of the equipment and process resulting in more effi cient operation longer trouble free service and f
7. Division 1 or 2 hazardous areas in accordance with NFPA 33 A13159 Flowmeter Safety AREA Tells where haz ards may occur Electrical Equipment aa Toxic Substanc es HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is uti lized in the process Arcing in the vicinity of flammable or combustible materials may oc cur 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 shut down indicates a problem in the system which requires correc tion An electrical arc can ignite coat ing materials and cause a fire or explosion Chemical Hazard Certain materials may be harm ful if inhaled or if there is con tact with the skin SAFEGUARDS Tells how to avoid the hazard Unless specifically approved for use in hazardous locations the power supply control cabinet and all other electrical equipment must be located outside Class or Il 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 flammable or combus tible 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 vol
8. Temperature 150 F 65 C Signal Output 30 000 PPG 8100 PPL Single Channel Standard 2 Channel Quadrature Optional Fiberoptic Optional Power 8 24 VDC Materials Body 303 Stainless Steel Gears DIN 1 4122 Stainless Steel Hardened Bushings Tungsten Carbide Shafts Tungsten Carbide Seal PTFE Filtration 100 Mesh maximum Connections Threaded 3 8 AN F Weight 4 8 lbs 2 18 Kg FM 14 01 INSTALLATION GENERAL INFORMATION The unit may be mounted using the bolt pattern shown in Figure 1 2 1 4 28 bolts should be used Always mount the flow meter with the gear faces perpendicular to the horizon of the earth i e vertical This minimizes the effect of gravity on the gears The direction of flow must be plumbed as marked on the side label of the meter The fluid inlet is opposite the sensor connection Although not absolutely necessary the meter should be plumbed such that the flow enters at the bottom of the meter and exits at the top This eliminates any possibility of air entrapment in the meter 1 4 28 THD x 0 50 DEEP Figure 1 Mounting Holes alalele 6543 A12720 00 Fiberoptic Receiver 1 2 7 o GND 4 Refer to drowings for controller for 24VD0 terminal and wire numbers White Source Ph Green Black Shielded cable to controller inputs Figure 2 Receiver Wiring FM 14 01 A13159 Flowmeter Installation
9. Using a 5mm Allen wrench remove all 4 bolts Pull the sensor section STRAIGHT apart from the gear pocket section If the body halves do not slide apart easily DO NOT pry them apart with screwdrivers etc Rather replace the bolts and only thread them in a few turns then tap FM 14 01 A13159 Flowmeter Maintenance the top of the bolts with a soft mallet while holding the top half of the body Clean and replace worn parts as necessary Install new gasket Install all parts in the order they were removed Install flatted portion of shafts toward gears see Fig 4 Push the two covers together aligning the pins and holes by hand MOUNTING FOOTPRINT 3MM ALLEN HEAD 1 4 28 THO x 0 50 DEEP Lar 73 gt TOP SECTION Sensor Opposite Side BOTTOM SECTION Shawing Geor Paskets FLUID OUTLET FLUID FLOW DIRECTION FLUID INLET ALIGNMENT PIN TYP Figure 3 Views of Flowmeter Body It may be necessary to tap the two halves of the flowmeter together with a soft mallet DO NOT use the bolts to pull them together as it may damage the alignment pins Snug all screws down Tighten the screws in the se quence pattern shown in Fig 3 to 13 lbs ft torque This is a cross pattern to insure proper gasket sealing Figure 4 View of Flatted Portion of Shaft 12 A13159 Flowmeter Parts A13159 Hexagon Flowmeter Parts List Item Partit Description Connector only for use only with A13159
10. aster easier troubleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified 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 fire codes and ordinances as well as NFP A 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servic ing this equipment The hazards shown on the following pages may occur during the normal use of this equipment Please read the haz ard chart beginning on page 2 FM 14 01 Tells where haz ards may occur Spray Area FM 14 01 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate opera tion and maintenance proce dures 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 Pow er Supply or Controller shut down indicates a problem in the system requiring correction A13159 Flowmeter Safety SAFEGUARDS Tells how to avoid the
11. aterials 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 fire or explosion is lost if the current over load sensitivity is not properly set Frequent power supply shutdown indicates a problem in the system which requires correction Always turn the control panel power off prior to flushing cleaning or working on spray system equipment Before turning high voltage on make sure no ob jects 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 fire 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 fire protection opera tion maintenance and housekeeping Reference OSHA NFPA 33 EN Norms and your insurance company requirements FM 14 01 Tells where haz ards may occur Spray Area High Voltage Equip ment FM 14 01 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 ca
12. ed Terminal Block A13634 00 Turck Option eno si Sands O Control gro 8 tOuncrolure FM 14 01 MAINTENANCE CALIBRATION The calibration value in pulses per liter or PPL will vary based on viscosity flow rate temperature and other factors Refer to appropriate associated equipment for calibra tion procedure TROUBLESHOOTING Flowmeter problems can be caused by improperly filtered fluid Particulates in the fluid can cause gear binding resulting in improper signals for the actual flow rate Maintain the fluid filters according to the instructions from the filter manufacturer If repeated disassembly and cleaning for remov al of solids and particulates occurs inspect the entire fluid supply system and evaluate the system cleaning cycle Fluid back up that is reverse flow can cause reacted catalyzed material to enter the flow meter Reverse flow will be detected by the 2K controls and the system will shut down if quadrature sensors are used The flowmeter should be cleaned immediately before the fluid sets up Under normal operation the sensors or electri cal connections will not require replacement SERVICING If flow appears blocked or the electronics fails to see pulses while flow is occurring follow the procedure below to disassemble the meter Disconnect sensor cable from the flowmeter sensor Remove meter for service to a suitable clean area to perform maintenance
13. er 10 A13159 Flowmeter Operation INTRINSICALLY SAFE OPERATION Hazardous Area Non Hazardous Area 24 VDC Power Supply Cable must be sealed off amp at booth wall according to local electrical code require ments A13633 00 PEF Option A13256 02 eee fin 11 NO rea ond Fin 12 CSa A Cui vnze uN loo sin 14 Segrai 6 910 Cp Contralor enn ol 8 Ouncrolure Grounded DIN Rail Senso Prost Dual Sensor PaP Option P amp F Barriers enc qreen 4 ya Grounded DIN Rail Hazardous Area Non Hazardous Area Cable must be sealed off at booth wall according to A13633 00 local electrical code requirements Stahl Option A13256 02 ln Sensor lea sea lola Ha 14 Seal E dut qn 6 uaeveture E a Grounded DIN Rail Sensor Pinot St A Optor tal tion Dual Sensor Stahl Barriers Hazardous Area Ain 12 Spat A Cu Grounded DIN Rail Non Hazardous Area Cable must be sealed off at booth wall according to local electrical code requirements A13633 00 Turck Option 24 VDC Power Supply liyezay A13256 02 Sensor fin 4 Dual Sensor Turck Barriers i amp Oat Grounded DIN Rail Ground
14. hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the ac cumulation 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 mainte nance When using solvents for cleaning e Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those solvents used for general cleaning must have a flash point at minimum of 5 C 9 F greater than the ambient temperature It is the end users responsibility to insure this condition is met 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 flammable 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 re quired 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 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
15. ir Ransburg May 2014 Fluid Flowmeter MODEL A13159 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 50 00 U S A13159 Flowmeter NOTES FM 14 01 A13159 Flowmeter Contents CONTENTS PAGE SAFETY 1 6 SAFETY PRECAUTIONS anii aa a ao ad au 1 HAZARDS SAFEGUARD Sid 2 6 INTRODUCTION 7 DESCRIPTION sisi aia 7 FLOW RATE AGGUBACO Y ocasion 7 REVERSE FLOW DETECTION unicidad aid 7 FLUID PASSAGE S cusco lito 7 SPECIFRICA TON Sci ASA ass 7 INSTALLATION 8 GENERAL INFORMATION Goin 8 REGEIVERWIRIN Gossip a ehh on ect iat eh etalon ata 8 EEECTRICAL NOSE e te Re a 8 SINGLE VS DUAL SENSOR INSTALLATIONS oo eeeee eee tener tere eeee seat eres seaeeeeeeteeenneeeeaeeeas 8 OPERATION 9 PRINCIPLE OF OBRERA TON dore ceeds AOS ad caves 9 AUTOMATIC CLEANING OF THE FLOWMETER 0 ee ceeeeseeeeeeeeseeceeeeeseeeeaeeeaeeseaeeeneeeeaeeeaeees 9 INTRINSICALLY SAFE OPERATION SINGLE SENSOR c cee eeeee cette eee ee ete eea eas 10 INTRINSICALLY SAFE OPERATION DUAL SENSOR 00sec eeeeeeeeee eee ee eee eeeeeeenenees 11 MAINTENANCE 12 CALIBRATION atar e tr ed a e a do de ne Le edo dd 12 TROUBLESHOOTING GUIDE arrendador ti ds 12 SERVICING ien A A i a A nes 12 PARTS 13 PARTS STi 13 WARRANTY POLICIES 14 LIMITED WARRANT Void A A AA tea 14 FM 1
16. l is compatible contact your coating supplier Any other type of solvent may be used with aluminum equipment A13159 Flowmeter Introduction INTRODUCTION GENERAL DESCRIPTION The A13159 Flowmeter has been developed for precise metering and monitoring of fluid flows The flowmeter in many cases surpass es the performance of meters currently used FLOW RATE ACCURACY High flow rate accuracies of 0 5 are achiev able with many fluids if the flowmeters are calibrated at or near the expected flow rates Even with wide flow rate swings such as when used with robots under analog control accuracies of 3 are achievable REVERSE FLOW DETECTION Dual output quadrature type sensors are available which allows reverse flow detection if necessary FLUID PASSAGES The Flowmeter requires 3 8 AN male fittings This style fitting eliminates flow dead space and also eliminates the need for specially designed fittings or adhesive inserts By creating a streamline fluid passage color change time of the meter is improved WATER BASED APPLICATIONS This Flowmeter is available in a fiberoptic version for water based high voltage conduc tive applications Also special tin coated gears are available A12715 01 to minimize corrosion and rust issues SPECIFICATIONS Flow Rate 01 1 00 GPM 40 mL min 4000 mL min Accuracy 3 5 system dependent Working Pressure 250 psi 17 bar MWP 100 F
17. pable of igniting coat ing materials Inadequate grounding will cause a spark hazard A spark can ignite many coating materials and cause a fire or explosion A13159 Flowmeter Safety 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 convey ors 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 insu lating 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 applica tor 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 flooring must be provided in the spray area Always turn off the power supply prior to flushing cleaning or working on spray system equipment Unless specifically approved for use in hazardous locations all electrical equipment must be located outside Class or Il
18. r from date of purchase WRAPPING THE APPLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY FM 14 01 RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO RE PLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATER IALS THERE ARE NO IMPLIED WAR RANTIES NOR WARRAN TIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUC TION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS EXCLUSIONS If in Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will assume no responsibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable A13159 Flowmeter Warranty Policies 14 Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Philips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 www ransburg com Technical Support Representative will direct you to the appropriate telephone number for or dering Spa
19. re Parts Form No LN 14 01 2014 Finishing Brands Americas Litho in U S A Models and specifications subject to change without notice 05 14
20. tage on make sure no objects are within the sparking distance Follow the requirements of the Material Safety Data Sheet supplied by coating material manufac turer 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 FM 14 01 Tells where haz ards may occur Spray Area FM 14 01 HAZARD Tells what the hazard is Explosion Hazard Incompatible Materials Halogenated hydrocarbon sol vents for example methylene chloride and 1 1 1 Trichloroethane are not chemi cally compatible with the alumi num that might be used in many system components The chemical reaction caused by these solvents reacting with alu minum can become violent and lead to an equipment explosion A13159 Flowmeter Safety SAFEGUARDS Tells how to avoid the hazard 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 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 materia
21. tate one or two proximity sensors detect the passing of each of those gear teeth Every time one of those gear teeth passes a proximity sensor the sensor sends a square wave pulse back to the controller indicating that one of those cavities of material has passed through the meter Flowmeters are typically calibrated by counting the number of pulses that occur when one liter of material has passed through the meter That value is typically called the calibration value or calibration factor and is expressed in pulses per liter ppl Although intuitively one might think that this value would not change from material to material that is not the case as it changes based on several factors These factors include but are not necessarily limited to viscosity flow rate temperature of the material percent of solids lubricity of the material solvent vs water based and whether or not the material is thixotropic or not It is therefore important that gear type flowmeters be calibrated with the material they are going to be subjected to for production and at the flow rates ex pected during production AUTOMATIC CLEANING OF THE FLOWMETER Fluid Line Air Purges Air purges are often used in automatic coating operations for rapid color changes and to minimize the amount of solvent required to flush out the old color Special considerations must be made when using air purges through the flowmeter 1 Lengthy air purges do not provide
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