FLOWMETER - Ransburg.com
Contents
1. 10 MAINTENANCE 11 FLOWME TER SERVIGING sisi seindecrtderinicdstxtoraneslausicacyvaccepeasardectnnusnnsacasavsserteasanaennagahartananiiicae 11 DISASSEMBLY 11 PARTS IDENTIFICATION 12 13 OY VIE TE 12 FLOWMETER PARISIUS oiiire iisas iiaea eaid ar iaa aiara iiaa 13 WARRANTY POLICIES 14 WMI TED 14 FM 14 02 Ransburg 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 information relates to USER SAFETY and PREVENTING EQUIPMENT PROBLEMS Tohelp yourecognize 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 ANOTE is information relevant to the procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your equipment2. 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 efficient 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 FM 14 02 Flowmeter Safety A WARNING The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified gt 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 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 NFPA 33 SAFETY STANDARD LATEST EDITION prior to installing operating and or servicing this equipment A WARNING 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 Ransburg FM 14 02 AREA Tells wh
3. 02 NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NOLIABILITY FORINJURY DAMAGE TO PROPERTY OR FORCONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION 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 willassume 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 14 Ransburg Flowmeter NOTES FM 14 02 15 Ransburg Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance 320 Phillips Ave Toledo Ohio 43612 1493 Telephone toll free 800 233 3366 Fax 419 470 2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts 2015 Finishing Brands Inc All rights reserved Form No FM 14 02 Models and specifications subject to change without notice Litho in U S A 01 15
4. Barriers Hazardous Area Non Hazardous Area 24 VDC Power Supply Cable must be sealed off at booth wall according to local electrical code requirements ian oaten 77220 or similar GND p cable Sq Wave assembly Signal to Signal Controller Sensor Pinout Grounded DIN Rail Single Sensor Stahl Barriers Hazardous Area Non Hazardous Area Power Supply Cable must be sealed off at booth wall according to local electrical code requirements 77220 or similar GND p cable Sq Wove assembly Signal to Signal Controller Grounded DIN Rail Sensor Pinout Single Sensor Turck Barriers FM 14 02 Grounded Terminal Block Ransburg Flowmeter Intrinsically Safe Operation INTRINSICALLY SAFE OPERATION cont Hazardous Area Dual Sensor P amp F Barriers Hazardous Area Dual Sensor Stahl Barriers Hazardous Area Dual Sensor Turck Barriers FM 14 02 cal asse Cable must be sealed off at booth wall according to local electrical code requirements Non Hazardous Area A13633 00 P amp F Option 77220 or similar ble mbly A13634 00 P amp F Option Cable must be sealed off at booth walt according to Non Hazardous Area local electrical code requirements A13633 00 Stahl Option 77220 or similar cable assembly Cable mus
5. 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 Flowmeter Safety 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 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 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 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 e
6. employed in all Binks and Ransburg products use shielded twisted pair cable and are therefore designed to minimize noise interference with the flowmeter signals These cables cannot however eliminate all spurious noise signals A WARNING gt It is important during installation to insure that the flowmeter cables not be run near within 12 noise generating devices such as large electric motors fluorescent lighting transformers ballasts etc A WARNING gt This meter may be installed in Class Division Group D locations when used in conjunction with the proper Zener Barrier Refer to pages 8 9 for more details Ransburg Flowmeter Intrinsically Safe 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 flowmeter sensor through the approved zener barrier Hazardous Area Non Hazardous Area Cable must be sealed off at booth wall according to local electrical code requirements A13632 00 P amp F Option or signals returning from the 24 VDC Power Supply A13256 01 Sensor similar GND assembly t Iae Signal Controller _ Sereor Grounded DIN Rail Single Sensor P amp F
7. ING 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 Division 1 or 2 hazardous areas in accordance with NFPA 33 Ransburg Toxic Substances FM 14 02 AREA Tells where hazards may occur Electrical Equipment Spray Area HAZARD Tells what the hazard is Electrical Discharge High voltage equipment is utilized in the process Arcing in the vicinity of flammable or combustible materials may occur 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 correction An electrical arc can ignite coating materials and cause a fire or explosion 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
8. SERVICE MANUAL FM 14 02 Ransburg JANUARY 2015 FLOWMETER MODEL A12712 00 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 Ransburg Flowmeter Contents CONTENTS PAGE SAFETY 1 5 FAZAR 2 5 INTRODUCTION 6 6 PLOW RATE 6 REVERSE FLOW IDE TEC ai aaa 6 eaaa REEN 6 SPECIFICATIONS ccc cana nts cnn vaivnetacean naa inmate neocon 6 INSTALLATION 7 7 ELECTRICAL 7 INTRINSICALLY SAFE OPERATION 8 9 HAZARDOUS AND NON HAZARDOUS AREA 1 00 0 cece cesses eeeeeeeeeseseeeneesesaneeeeseseaeeeessnnees 8 9 OPERATION 10 PIRINGIPEE OP OPERATION ta ening evans 10 CALIBRATION iadi 10 AUTOMATIC CLEANING OF
9. d 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 replacement MOUNTING FOOTPRINT TORQUE SEQUENCE 5MM SOCKET HEAD 1 4 28 THD x 0 50 DEEP Ly 73 TOP SECTION Sensor Opposite Side BOTTOM SECTION FLUID OUTLET NA A 5 FLUID FLOW AUGNMENT PIN TYP FLUID INLET DIRECTION Figure 1 Views of Flowmeter Body FM 14 02 Flowmeter Maintenance DISASSEMBLY REASSEMBLY Refer to Figure 3 Disconnect sensor cable 1 from the flowmeter sensor 2 or 3 Remove meter for service to a suitable clean area to perform maintenance Using a 5mm hex key wrench remove all 10 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 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 TFE O ring 8 Install all parts in the order they were removed Install flatted portion of shafts 6 toward gears see Figure 2 Push the two covers together aligning the pins and hol
10. ere hazards may occur Spray Area HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures 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 Controller shutdown indicates a problem in the system requiring correction Flowmeter Safety 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 flushing or maintenance 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 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 mu
11. es by hand NOTE Flowmeter halves can be assembled backwards Make sure to align plates on sides of flowmeter halves when assembling 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 Flatted Portion of Shafts 11 Ransburg Flowmeter Parts Identification PARTS IDENTIFICATION Ap Figure 3 Flowmeter FM 14 02 12 Ransburg Flowmeter Parts Identification FLOWMETER PARTS LIST Figure 3 Ce 1 77220 00 Flowmeter Cable Assembly 50 ee 2 cables can be placed in series A13256 01 Single Pickup Sensor Assembly A12256 02 Dual Pickup Sensor Assembly M6x1x30mm L Socket Head Cap Screw 5 Upper Housing Cannot be purchased separately A12716 00 Shaft Set 2 For use in A12712 00 Flowmeter only Use 76271 00 in 76251 01 RF 1 flowmeter assemblies A12715 00 Gear Set 2 For use in A12712 00 Flowmeter only Use 76270 00 in 76251 01 RF 1 flowmeter assemblies A12715 01 Coated Gear Set 2 For use in A12712 00 flowmeter only 76272 00 TFE O Ring Set 5 ee LSF10033 00 3 8 AN x 3 8 ODT Fitting Optional fitting for connection to 3 8 O D tubing 77104 00 3 8 AN x 3 8 NPS M Fitting Optional fitting for connection to 3 8 female connector 77105 00 3 8 AN x 1 4 NPS M Fi
12. es 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 itis recommended 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 10 Ransburg MAINTENANCE FLOWMETER SERVICING 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 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 detecte
13. he 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 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 expected during production CALIBRATION It is important that the flowmeter be calibrated periodically as the calibration value in pulses per liter or PPL will vary based on viscosity flow rate temperature wear and other factors Refer to appropriate associated equipment documentation for the proper calibration procedure FM 14 02 Flowmeter Operation 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 the lubrication the flowmeter gears require Lubrication is normally provided by the metered fluid or solvent 2 Air purg
14. propriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Reference OSHA NFPA 33 EN Norms and your insurance company requirements Ransburg FM 14 02 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 fire or explosion 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 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 GROUND
15. st 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 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 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 Ransburg FM 14 02 AREA Tells where hazards may occur Spray Area General Use and Maintenance HAZARD Tells what the hazard is Explosion Hazard Improper or inadequate operation and maintenance procedures 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 Controller shutdown indicates a problem in the system requiring correction Improper operation or maintenance may create a hazard Personnel must be properly trained in the use of this equipment Flowmeter Safety SAFEGUARDS Tells how to avoid
16. streamlined fluid passage color change time of the meter is improved 01 50 GPM 04 1 9 LPM Accuracy 2 Viscosity above 50cp Working Pressure 5 000 psi 345 bar MWP 100 F Temperature 40 F 0 120 F Signal Output Single Channel or 2 Channel Quadrature 30 000 PPG 8100 PPL Power 9 24 VDC Materials Body 303 Stainless Steel Gears DIN 1 4122 Stainless Steel Bushings Tungsten Carbide Shafts Tungsten Carbide Seal TFE Filtration 120 Mesh maximum Connections Threaded 3 8 AN F Weight 4 8 Ibs 2 2 Kg FM 14 02 Ransburg INSTALLATION GENERAL INFORMATION The unit may be mounted using the bolt pattern 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 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 OUTLET PORT 1 4 20 THD x 0 675 DEEP 2 PLACES 3 30 DIA INLET PORT Figure 1 Mounting Holes FM 14 02 Flowmeter Installation ELECTRICAL NOISE All flowmeter cable assemblies
17. t be sealed off at booth walt according to local electrical code requirements A13634 00 Stahl Option Non Hazardous Area A13633 00 Turck Option 77220 or similar cable assembly Grounded DIN Rail Grounded Terminal Block A13634 00 Turck Option 24 VDC Power Supply 8 GND 7 Sq Wove ADC Signals to Controller Signal B Quadrature Grounded DIN Rail Grounded DIN Rail 24 VDC Power Supply GHD 7 Sq Wave A C Signals to Controller Signal 8 Quadrature Grounded DIN Rail Grounded DIN Rail 24 VDC Power Supply GND La Sq Wave Signals to Controller Signal B Quadrature Ransburg 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 rotate 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 t
18. tc 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 coating supplier Any other type of solvent may be used with aluminum equipment Ransburg INTRODUCTION DESCRIPTIONS The 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 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 2 are achievable SPECIFICATIONS Flow Rate Flowmeter Introduction REVERSE FLOW DETECTION The sensors pickups are available in either single sensor or dual sensor versions If it is necessary to sense reverse flow of the material the dual sensor version should be used The dual sensor version outputs two square waves in quadrature mode so that sensing circuitry can determine both flow rate and direction FLUID PASSAGES The flowmeter requires 3 8 AN male fittings This style of fitting eliminates flow dead space and also eliminates the need for specially designed fittings or TFE inserts By creating a
19. 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 specifically approved for use in hazardous locations all electrical equipment must be located outside Class or Division 1 or 2 hazardous areas in accordance with NFPA 33 Test only in areas free of flammable 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 fire 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 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 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 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 ap
20. tting Optional fitting for connection to 1 4 female connector 76850 00 Fitting Kit Optional fitting kit to connect to 1 4 O D tubing NOTE The flowmeters are shipped from the factory with white TFE O Rings Replacement O Rings will be tinted blue to indicate that they are metric for use in the A13159 A12712 and A12713 flowmeters FM 14 02 13 Ransburg Flowmeter Warranty Policy 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 RANSBURGAPPROVED PARTS VOID ALL WARRANTIES 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 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC SHRINK WRAP ETC WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE FM 14
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