FM-00-01.2 RF-1 Flow Meter (76251-01) (Draft 7-23
Contents
1. 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 equipment 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 material is compatible contact your material supplier Any other type of solvent may be used with aluminum equipment FM 00 01 3 rrvrRansburg RF 1 Flowmeter Safety AREA HAZARD SAFEGUARDS Tells where hazards may occur Tells what the hazard is Tells how to avoid the hazard General Use and Use of hand tools may cause Risk is reduced by avoiding or lessening the listed Maintenance cumulative trauma disorders hazards CTD s CTD sormusculoskeletal disorders involve damage to the CTD s can also be caused by such activities as hands wrists elbows shoulders sewing golf tennis and bowling to name a few neck and back Carpal tunnel syndrome andtendinitis such as Pain tingling or numbness in the shoulder forearm tennis elbow or rotator cuff wrists hands or fingers especially during the night syndrome are examples of CTD s may be early symptoms of a CTD Do not ignore them Should you experience any such symptoms CTD s when using handtools tend se2. 7vvRansburg SERVICE MANUAL FM 00 01 3 Replaces FM 00 01 2 July 2007 RF 1 FLOWMETER 76251 01 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Manual for future reference Service Manual Price 15 00 Euro 20 00 U S rrvvRansburg NOTE This service manual has been superceded from service manual number FM 00 01 2 to service manual number FM 00 01 3 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual FM 00 01 3 ir Ransburg CONTENTS SAFETV SAFETV PRECAUTIONS HAZARDS SAFEGUARDS RF 1 Flowmeter Contents PAGE 1 6 INTRODUCTION DESCRIPTIONS FLOW RATE ACCURACY REVERSE FLOW DETECTION FLUID PASSAGES SPECIFICATIONS INSTALLATION INSTALLATION MAINTENANCE PARTS IDENTIFICATION RF 1 FLOWMETER PARTS LIST WARRANTY POLICIES LIMITED WARRANTIES FM 00 01 3 RF 1 Flowmeter Safety SAFETV SAFETV PRECAUTIONS Before operating maintaining or servicing anv ITW Ransburg electrostatic coating svstem read and understand all of the technical and safetv literature for vour ITW Ransburg products This manual contains information that is important for vou to know and understand This information relates to USER SAFETV and PREVENTING EQUIPMENT PROBLEMS To help you recog nize this information we use the following sym bols
3. Personnel mustbe given training in accordance with Maintenance may create a hazard the requirements of NFPA 33 Personnel mustbe properly trained Instructions and safety precautions must be read in the use of this equipment and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance andhousekeeping Reference OSHA NFPA 33 and yourinsurance company requirements Always turn power to the power supply OFF unplug the electrical cord from its outlet and remove the front panel fuse before opening the power supply door If necessary lock the power supply out so that it cannot be turned ON until the work is finished Whenever removing high voltage cables from equipment ground the contact end of the cable by holding the cable such that the contact touches earth ground for severalseconds Do nottouch the contact until it has been grounded This will reduce the possibility of residual charge causing electrical shock The High Voltage Multiplier Assembly contains energy storage components that can cause serious shock injury and therefore is not field repairable Warranty will be voided if the High Voltage Multiplier seal is broken If the High Voltage Multiplier is defective contact your authorized ITW Ransburg representative for exchange or repair The High Voltage Multiplier and high voltage cable contain significant capacitance
4. FLOWMETER SERVICING Flowmeter problems can be caused bv improperly filtered fluid Particulates in the fluidcan cause gear binding resulting inimproper signals for the actual flow rate Maintain the fluid filters according to the instructions from the filter manufacturer If repeated disassembly and cleaning for removal 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 The flowmeter should be cleaned immediately before the fluid sets up Under normal operation the magnetic sensors or electrical connections will not require replace ment SERVICE Disconnect sensor cable 1 from the flowmeter sensor 2 Remove meter for service to a suitable clean area to perform maintenance Using a 3 16 Allen wrench remove all 10 3 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 a few of the bolts and only thread them in a few turns then tap the top of the bolts with a soft mallet while holding the top half of the body Pull the gears and pins from the gear pocket section Clean and replace worn parts as necessary Install new teflon o ring 7 Install all p
5. Lower Housing Cannot be purchased seperatelv N A Alignment Pin Pins press fitted in and cannot be removed or replaced LSF10033 00 3 8 AN x 3 8 ODT Fit Optional fitting 77104 00 3 8 AN x 3 8 NPSM m Optional fitting 77105 00 3 8 AN x 1 4 NPSM m Optional fitting 76804 00 01 3 8 OD SS Tubing Used when replacing TR SSEH series flowmeters on 2k Controls or 2k880 fluid panels FM 00 01 3 76850 00 Fitting Kit Used when 1 4 OD tubing is required or preferred 14 RF 1 Flowmeter Warranty Policies 15 irvvRansburg WARRANTY POLICIES LIMITED WARRANTY ITW Ransburg will replace or repair without charge any part and or equipment that fails within the specified time see below because of faulty workmanship or material provided that the equipment has been used and maintained in accordance with ITW 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 ITW RANSBURG APPROVED PARTS VOIDS ALL WARRANTIES SPARE PARTS One hundred and eighty 180 days from date of purchase exceptfor rebuilt parts any part number ending in R for which the warranty period is ninety 90 days 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 warran
6. 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 pro cedure in progress While this manual lists standard specifications 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 ITW Ransburg equipment manu als 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 efficient operation longer trouble free service and faster easier trou bleshooting If you do not have the manuals and safety literature for your Ransburg system con tact your local ITW Ransburg representative or ITW Ransburg ryRansburg A WARNING The user MUST read and be familiar with the Safety Section in this manual and the ITW Ransburg safety literature therein iden tified This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care
7. cause a fire or explosion is lost if safetv circuits are disabled during operation Frequent power supply shutdown indicates a problem in the system which requires correction Anelectrical arc can ignite coating materials and cause a fire or explosion Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloro ethane 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 rmyRansburg 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 fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 and yourinsurance company requirements The power supply optional remote control cabinet and all other electrical equipment must be located outside Class 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 flammable 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
8. that will store charge Allow approximately 10 seconds for this charge to bleed off before opening the cabinet door or removing the high voltage cable from the power supply or spraygun 5 FM 00 01 3 Ir Ransburg RF 1 Flowmeter Safety NOTES FM 00 01 3 6 RF 1 Flowmeter Introduction INTRODUCTION DESCRIPTIONS The RF 1 Flowmeter has been developed for precise metering and monitoring of fluid flows The flowmeter in many cases surpasses the performance of meters currently used FLOW RATE ACCURACY Flow rate accuracies of 0 5 are not uncommon with many fluids ifthe 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 2 are achievable REVERSE FLOW DETECTION Sensors are of the quadrature type which allows reverse flow detection if necessary Under conditions where reverse flow detection is not necessary only one sensor output is used leaving the second sensor output as a spare output that can be used if the first sensor should ever fail FLUID PASSAGES The RF 1 requires 3 8 AN male fittings This style fitting eliminates flow dead space and also eliminates the need for specially designed fittings or Teflon inserts By creating a streamline fluid passage color change time of the meter is improved Iru Ransburg SPECIFICATIONS Material Viscosity Range Flow Rate Accuracy Wor
9. arts the order they were removed Install flated portion of shafts 5 toward gears see Figure 1 Push the two covers together aligning the pins and holes by hand n O O ALIGNMENT HOLE e _ O A gt pica b o N PAN al a A O Or Q x 7 ARA e Irw Ransburg MOUNTING FOOTPRINT TORQUE SEQUENCE 2 x 1 4 20 THREAD 77 0 O N Va N 76 2 Xe 4 f 3 16 ALLEN HEAD O 3 5 78 el 10 1 SENSOR SECTION GEAR POCKET SECTION PINE ALIGNMENT PINS FLUID OUTLET A D Da J ki FLUID INLET RELIEF CUT i ue NO yy wat VU DIRECTION gt L RELIEF CUT Figure 1 NOTE There is only one way to install the sen sor section and the gear pocket section Views of Flow Meter Body Snug all screws down Tighten the screws in the sequence pattern shown in Figure 1 to 13 Ibseft torque This is a cross pattern to insure proper gasket sealing POSITION FLATS Figure 2 View of Flated Portion of Shafts FM 00 01 3 rrvrRansburg RF 1 Flowmeter Maintenance CALIBRATION NOTES Refer to appropriate associated equipment for calibration procedure AUTOMATIC CLEANING OF THE FLOWMETER Fluid Line Air Purges Air purges are often used in automatic coating operations for rapid colorchanges andto 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 Air purges do not provide the lubri
10. cation 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 recommended as the most efficient way of flushing flowmeters 6 Air purge cycles are not recommended in water based applications FM 00 01 3 12 RF 1 Flowmeter Parts Identification Ir Ransburg PARTS IDENTIFICATION Figure 3 RF 1 Flowmeter 13 FM 00 01 3 rrwvRansburg RF 1 Flowmeter Parts Identification RF 1 FLOWMETER PARTS LIST Figure 3 TR SSEH 585 Description Electrical Connector Same connection as TR SSEH series flowmeters 76252 00 Sensor Assembly See Service Bulletin 98 11 revised for interchangeability with TR SSEH 793 2 sensors 1 4 20 x 1 1 4 L Socket Hd Cap Screw Must be grade 8 or better N A Upper Housing Cannot be purchased seperately 76271 00 Shaft Interchangeable with TR SSEH 604 76270 00 Gear Stamped with an F or G to distinguish from TR SSEH 603 gears 76272 00 Teflon O Ring N A
11. e a physician immediately Other early symptoms to affect the upper extremities may include vague discomfort in the hand loss of Factors which may increase the J manual dexterity and nonspecific pain in the arm risk of developing a CTD include Ignoring early symptoms and continued repetitive use of the arm wrist and hand can lead to serious 1 High frequency of the activity disability 2 Excessive force such as gripping pinching or pressing with the hands and fingers Extreme or awkward finger wrist or arm positions Excessive duration of the activity Tool vibration Repeated pressure ona body part 7 Working in cold temperatures Toxic Substances Certain material maybe harmful if Follow the requirements of the Material Safety Data inhaled or if there is contact with Sheet supplied by coating material manufacturer the skin Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a maskor respirator whenever there is achance 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 00 01 3 4 RF 1 Flowmeter Safety rm Ransburg AREA HAZARD SAFEGUARDS Tells where hazards may occur Tells what the hazard is Tells how to avoid the hazard General Use and Improperoperation or maintenance
12. eneral cleaning must have flash points above 100 F 37 8 C 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 flammable 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 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 with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials Paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements FM 00 01 3 2 RF 1 Flowmeter Safety AREA Tells where hazards may occur General Use and Maintenance Electrical Equipment Explosion Hazard Incompatible Materials HAZARD Tells what the hazard is Improperoperation or maintenance mav create a hazard Personnel mustbe properly trained in the use of this equipment High voltage equipmentis utilized Arcing in areas of flammable or combustible materials mavoccur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that mav
13. king Pressure Temperature Signal Output Power Materials Body Gears Bushings Shafts Seal Filtration Connections Weight 01 50 GPM 04 1 9 LPM 0 5 system dependent 500 psi 345 bar MWP 100 F 180 F 85 C 2 Channel Quadrature 30 000 PPG 8100 PPL 8 24 VDC 303 Stainless Steel Stainless Steel Hardened Carbide Carbide Teflon 100 Mesh maximum Threaded 3 8 AN F 4 5 Ibs 2 0 Kg FM 00 01 3 Ir Ransburg RF 1 Flowmeter Introduction NOTES FM 00 01 3 8 RF 1 Flowmeter Installation Ir Ransburg INSTALLATION The unit may be mounted using the bolt pattern NOTES shown in Figure 1 2 1 4 20 bolts should be used Always mount the flowmeter 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 The meter should be plumbed such that flow enters at the bottom of the meter and exits at the top This eliminates any possibility of air entrepment in the meter A WARNING gt This meter may be installed in Class Division Group D locations when used in conjunction with the proper Zenner Barrier 9 FM 00 01 3 Ir Ransburg FM 00 01 3 NOTES RF 1 Flowmeter Installation RF 1 Flowmeter Maintenance 11 MAINTENANCE
14. l Price to the Back Cover 6 Revised Contact Information on the Back Cover FM 00 01 3 Service Manual Price 15 00 Euro 20 00 U S Manufacturing 1910 North Wavne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www itwransburg com Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts STO Form No FM 00 01 3 ISO 9001 2007 Illinois Tool Works Inc All rights reserved Litho in U S A Models and specifications subject to change without notice MILO 07 07 END D MIA
15. should be taken to ensure the the WARNINGS and safety requirements for oprating and servicing the equipment are followed The user should be aware of and adhere to ALL local building and fire codees and ordinances as well as NFPA 38 prior to installing operating and or servicing this equipment A WARNING Thehazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 FM 00 01 3 rrvrRansburg RF 1 Flowmeter Safety AREA HAZARD SAFEGUARDS Tells where hazards may occur Tells what the hazard is Tells how to avoid the hazard Spray Area Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically Improper orinadequate operation and maintenance procedures will Spray areas must be kept clean to prevent the cause a fire hazard accumulation of combustible residues Protection against inadvertent Smoking must never be allowed in the spray area arcing that is capable of causing fire or explosion is lostif any safety The high voltage supplied to the atomizer must be interlocks are disabled during turnedoffpriorto cleaning flushing or maintenance operation Frequent power supply shutdown indicates a problem in When using solvents for cleaning the system requiring correction Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those used for g
16. ty period is ninety 90 days EQUIPMENT When purchased as a complete unit i e guns power supplies control units etc is one 1 vear from date of purchase WRAPPING THE APPLICATOR IN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTV ITW RANSBURG S ONLV OBLIGATION UNDER THIS WARRANTV IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ITW RANSBURG ASSUMES NO LIABILITV FOR INJURV DAMAGE TO PROPERTV OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BV PURCHASER OR OTHERS EXCLUSIONS EXCLUSIONS If in ITW Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained ITW Ransburg will assume no responsibility for repair orreplacement ofthe item or items The purchaser therefore willassume all responsibility for any cost of repair or replacement and service related costs if applicable FM 00 01 3 Ira Ransburg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual FM 00 01 1 to make the following changes 1 Added Service Manual Price to the Front Cover 2 Added Safety Section 3 Added Warranty Section 4 Added Manual Change Summary page 5 Added Service Manua
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