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LN-9240-02.1 - Ransburg.com

1. CONNECT TO RIL REGULATOR LOW 3 DR 1 REGULATED FLUID OUT CONNECT TO FLUID DUMP L VALVE 1 J DR 1 Li HIGH FLOW AIR PILOT IN CONNECT TO RIH REGULATOR HIGH FLUID OUT MTI AIR LOW AIR HIGH Figure 22 78719 xx Fluid Regulator Assembly Low Flow w Fluid amp Air Line Package Recirculating Fluid Return 58 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78719 xx FLUID REGULATOR ASSY LOW FLOW W FLUID amp AIR LINE PACKAGE Recirculating PARTS LIST Figure 22 Ez DR 1 Fluid Regulator Assembly Low Flow 2 Stage See Table A Adapter Swivel 1 4 NPSF x 1 4 NPTM SST 101 9120 Fitting Female Run Tee 3 8 O D Tube x 1 4 NPT 78721 06 Tube Fluid Supply 3 8 O D x 035 Wall Fitting Paint 1 4 O D Tube x 1 8 NPSM Fitting Swivel Male Elbow 5 32 O D Tube x 10 32 Thread Cap 5 32 O D Tube Yellow Identification For 78719 41 thru 51 Blue Identification For 78719 61 thru 71 Tubing 5 32 x 106 I D Yellow Nylon For 78719 41 thru 51 Blue Nylon For 78719 61 thru 71 Cap 5 32 O D Tube Orange Identification For 78719 41 thru 51 Gray Identification For 78719 61 thru
2. tette nanda 62 TRIGGER amp DUMP VALVE ASSY PARTS LIST 64 BULKHEAD PLATE FITTING LAYOUT PARTS LIST 66 TURBODISK 2 AIR TURBINE ASSY PARTS LIST 68 WARRANTY POLICIES 70 LIMITED WARRANTY esse tocca si is 70 APPENDIX 71 74 PAINT AND SOLVENT SPECIFICATIONS 71 VISCOSITY CONVERSION 72 VOLUMETRIC CONTENT OF HOSE OR TUBE 74 LN 9240 02 1 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 USERSAFETY 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 seriousinjury ifinstructions are not followed A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury A NOTE is information relevant to the procedure in progress While this manual lists standard specifications and service procedures some minor deviations may be found between this literature and your e
3. 19514 FSI SENSE EE LJ9UYSH m lt 9 m in rs lt o o Sele lo lole 5 sees se 2 olo Se 6 T Im R o au ejejol e xliojelje ia x vej eljei i ix ol eloe n el e el e 3s10d1nu3d A lalala mim TT 7 m n 0 SIR csi n ey s im R S N o x c x e o o A 95104 ur N oP J cv INT NTN m m m Jo T 7 7 T o n L lt VISCOSITY CONVERSION CHART LN 9240 02 1 74 Turbodisk 2 Appendix Ransburg O gt o U VISCOSITY CONVERSION CHART 424153 6 7 51295 eolelelelelelejelelelelelele slsisis O OD I OP IO S O OI IO 5 5 m e S d EN e 5 CN OD 2 j Ni 8 55 Z Z MI 85 519 mia sqa4 sie s E 21 Jaupsey lqqng JoupJer Sei r EE gt GE Lo EENS TT e FEE TT UM HE EE EE EE Le eee deal betente ele ele e sisis eje esiodnue Sisjalelsiela 218 5 ole eere Q ole ole ololole aslod Q m 9 9 in 5 S 9 fe All viscosity comparisons are as accurate
4. Green Identification For 78722 01 Natural Identification For 78722 02 Tubing 5 32 x 106 I D 222200 E Green Nylon For 78722 01 Natural Nylon For 78722 02 Tubing 1 4 x 170 I D FEP 1 Fitting Reducing Adapter 1 8 NPT M x 1 4 NPT F SST Tubing 1 2 O D x 3 8 I D FEP 7 5 2 Fitting Male Elbow 1 4 O D Tube x 1 4 NPT SST LSFI0007 01 Tubing 1 4 O D x 170 I D FEP 76698 01 6 75 5 1 1 1 5 70607 01 Tool Valve Not Shown CCV 7 Ferrule Back Tube 1 2 70606 05 ET D DA U LN 9240 02 1 65 Turbodisk 2 Parts Identification Ransburg nn 4 ce Figure 26 78729 Upper Turbodisk 2 Bulkhead Plate Fitting Layout Reference Figures 3a amp 3b 66 LN 9240 02 1 Ransburg 78729 UPPER TURBODISK 2 BULKHEAD PLATE FITTING PARTS LIST Figure 26 P1D Fitting Subassembly 78730 01 P1DL Fitting Subassembly 78730 02 3 4 P1S Fitting Subassembly 3 8 LD 1 4 LD P1R Fitting Subassembly 3 8 LD 1 4 LD R2H Fitting Subassembly 78730 12 EE R2L Fitting Subassembly 78730 13 1 12 gt P2S Fitting Subassembly SelectOption 3 8 LD 1 4 ID P2R Fitting Subassembly SelectOption 3 8 LD 1 4 LD T A2 Fitting Subassembly 78730 22 Note Reference Figure 3B for fitting identification designation LN 9240 02 1 Turbodisk 2 Parts Identification 67 Turbodisk 2 Parts Identification Figure 27 78175 xx T
5. 17 7 LX VAT Nut Hex 9 16 1 4 O D Tube SST 70591 01 Ferrule Front Tube 1 4 70607 01 Fitting Fluid Female 1 4 O D Tube Quick Disconnect 78702 01 Fitting Fluid Female 3 8 O D Tube Quick Disconnect 78702 02 Tubing 3 8 O D x 1 4 I D FEP SSP 5020 Ferrule Back Tube 1 4 70606 01 LN 9240 02 1 Turbodisk 2 Parts Identification 53 Turbodisk 2 Parts Identification Ransburg Figure 20 78714 xx High Flow Fluid Regulator Assembly w Fluid amp Air Line Package 54 LN 9240 02 1 wes HIGH FLOW FLUID REGULATOR ASSY W IBL Ransburg pure 20 TUM A AB LA RAGA cation 78714 xx HIGH FLOW FLUID REGULATOR ASSY W FLUID amp AIR LINE PACKAGE PARTS LIST 20 oso p Assemb Fitting Male Elbow 1 2 O D Tube x 1 2 NPT For 78714 01 amp 02 3 8 O D Tube x 1 2 NPT For 78714 03 amp 04 Fitting Male Adapter NEE 1 2 NPT x 1 2 ODD Stem For 78714 01 amp 02 1 2 NPT x 3 8 O D Stem For 78714 03 amp 04 77768 02 1 4 ring Suiv vae Hon S82 00 Tex rrr roro T Cap 5 32 OD Tube LC Yellow Identification For 78714 01 amp 03 Blue Identification For 78714 02 amp 04 6 Eng Male Connector 5220D Tubex TENT panen 1 Tubing 5 32 O D x 10610 FE Yellow Nylon For 78714 01 amp 03 77536 07 6 Blue Nylon For 78714 02 amp 04 7755 04 Fitting Fluid Female Quick Disconnect N
6. 2013 Ransburg All rights reserved Fax 877 852 7796 Fax 877 852 7796 Fax 800 359 2341 Fax 419 470 2071 Trademarks indicated with are registered with the United States Patent and Trademark Office by Ransburg Patents issued and pending in the United States Patent and Trademark Office Form LN 9240 02 1 Ransburg Industrial Systems is an ISO 9001 compliant company registered with Factory Mutual Litho in U S A Models and specifications subject to change without notice 01 13
7. AREA Tells where hazards HAZARD SAFEGUARDS Tells what the hazard is Tells how to avoid the hazard may occur Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically Improper or inadequate opera tion 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 lost if any safety The high voltage supplied to the atomizer must be interlocks are disabled during turned off prior to cleaning flushing or maintenance operation Frequent power supply shutdown indicates a probleminthe When using solvents for cleaning 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 general cleaning must have flash points above 100 F 37 8 C Spray booth ventilation must be kept at the rates required by NFPA 33 2000 Edition 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 modific
8. T Nie Lu sri r L 2 2 Figure 9 Typical Trigger and Dump Valve Application with High Flow Fluid Regulator Schematic Dual Fluid Supply Option Reference Figure 14 32 LN 9240 02 1 Ransburg Turbodisk 2 Maintenance many re iiie E EE T ID IT i i m rim Figure 10 Typical Trigger and Dump Valve Application with DR 1 Fluid Regulator Schematic Dual Fluid Supply with Recirculating Option Reference Figure 15 LN 9240 02 1 33 Turbodisk 2 Parts Identification Ransburg PARTS IDENTIFICATION 78715 TURBODISK 2 ASSEMBLY MODEL IDENTIFICATION Turbodisk 2 Assemblies are available with the various options as follows Model No 78715 xx xx DR 1 Fluid Regulator Ratio Option See Table B Dash required only when applicable Upper amp Lower Turbodisk 2 Sections Fluid Control Parts and Air Motor See Table A Basic Part Number Figure 11 Turbodisk 2 Assembly Standard Model Identification TABLE A Figure 11 Basic Turbine Air Heater amp Disk Turbodisk2 AirMotor Filter Reg Mounting Assy Assy Nut B gt Description No valves Down Feed CW Single Fluid System 3 8 ID Tubing Option No valves Down Feed CW Single Fluid System 1 4 ID Tubing Option No valves Down Feed CW Dual Fluid System 3 8 ID Tubing Option No valves Down Feed CW Dual Fluid System 1 4 ID Tubing Option No valves Down Feed CC
9. 71 Tubing 5 32 OD x 106 I D Orange Nylon For 78719 41 thru 51 Silver Nylon For 78719 61 thru 71 78720 00 70589 05 72070 11 77545 12 2 77545 01 2 77536 07 8 5 77536 04 8 5 Ec E Si 7753608 7753606 Fitting Male Connector 5 32 O D Tube x 1 16 NPT 78716 01 12 Tubing 3 8 x 1 4 I D FEP SSP 5020 _____ 8 Nut Hex 11 16 3 8 O D Tube SST 70591 03 2 14 Ferrule Back Tube 3 8 7050603 2 Ferrule Front Tube 3 8 70607 03 HA Fitting Fluid Female 3 8 O D Tube Quick Disconnect 78702 02 Tubing 1 4 O D x 156 I D FEP TABLE A Figure 22 Assembly Regulator Regulator Ratio 78719 41 78719 42 7871943 7871944 78719 45 7871546 787195 787151 78719 62 78719 63 ala AJN ai ai alela w S BRIN LN 9240 02 1 55994 23 59 Turbodisk 2 Parts Identification Ransburg Figure 23 78781 Turbodisk 2 Air Heater and Filter Regulator Assembly 60 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78781 TURBODISK 2 AIR HEATER amp FILTER REGULATOR ASSEMBLY PARTS LIST Figure 23 LN 9240 02 1 61 Turbodisk 2 Parts Identification Figure 24 78189 Turbodisk 2 Quick Release Fairing Assembly 62 Ransburg LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78189 TURBODISK 2 QUICK RELEASE FAIRING ASSEMBLY PARTS LIST Fi
10. EXCLUSIONS If in Ransburg s opinionthe 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 LN 9240 02 1 Ransburg APPENDIX RECOMMENDED VISCOSITY USING A ZAHN NO 2 REA EFM 18 TO 30 SEC REM M907M 18 TO 30 SEC NO 2 HAND GUN 20 TO 60 SEC PAINT AND SOLVENT SPECIFICATIONS TURBODISK 20 TO 60 SEC Turbodisk 2 Appendix AEROBELL AEROBELL AEROBELL 33 RMA 101 20 TO 60 SEC PAINT ELECTRICAL RESISTANCE 1MQ 1 TO 1TO1MQ 1MQ TO oo TO oo RECOMMENDED DELIVERY UP TO 1000 cc min 1500 cc min GUIDE TO USABLE SOLVENT SELECTION CHEMICAL COMMON CATEGORY CAS EVAP NAME NAME NUMBER Methylene Chloride DICHLOROMETHANE Chlorinated Solvents 180 cc min 75 09 2 1000 cc min 500 cc min ELECTRICAL RESISTANCE HIGH METHYL ACETATE Esters 79 20 9 LOW VM amp P NAPHTHA Naptha Aliphatic Hydrocarbons 803 232 4 HIGH ACETONE Ketones 67 64 1 LOW BENZENE Aromatic Hydrocarbons 71 43 2 HIGH ETHYL ACETATE Esters 141 78
11. Fitting Female Connector 3 8 O D Tube x 1 4 NPT 41 FTC 1005 MEE Har Tube Fluid Supply 3 8 O D x 035 Wall Fitting Paint 1 4 O D Tube x 1 8 NPSM Fitting Swivel Male Elbow 5 32 O D Tube x 10 32 Thread Cap 5 32 O D Tube Yellow Identification For 78719 01 thru 11 Blue Identification For 78719 21 thru 31 Tubing 5 32 O D x 106 I D Yellow Nylon For 78719 01 thru 11 Blue Nylon For 78719 21 thru 31 Cap 5 32 O D Tube Orange Identification For 78719 01 thru 11 Gray Identification For 78719 21 thru 31 Tubing 5 32 x 106 I D Orange Nylon For 78719 01 thru 11 Silver Nylon For 78719 21 thru 31 78720 00 70589 05 72070 11 77545 13 77545 11 2 77536 08 6 25 77536 06 6 25 Fitting Male Connector 5 32 O D Tube x 1 16 78716 01 2 Tubing 1 4 x 156 I D FEP 55994 23 i Nut Hex 11 16 3 8 O D Tube SST 70591 03 Ferrule Back Tube 3 8 70606 03 Ferrule Front Tube 3 8 70607 03 Fitting Fluid Female 3 8 O D Tube Quick Disconnect TABLE A Figure 21 Assembly Regulator Regulator Ratio 78719 04 7415104 18 78719 05 7871921 741510 __ 12 O 78719 23 7415103 _ 16 78719 25 1 2 1 4 1 6 1 8 1 3 13 1 2 1 4 1 6 1 8 1 3 a LN 9240 02 1 78702 02 57 Turbodisk 2 Parts Identification Ransburg CONNECT TO 15 PAINT 1 SUPPLY LINE CONNECT TO PIR PAINT 1 RETURN LINE
12. as XE with existing information Comparisons are made with a material having a specific gravity of 1 0 Note 75 LN 9240 02 1 Turbodisk 2 Appendix Ransburg VOLUMETRIC CONTENT OF HOSE OR TUBE English Units Cross Length Section 5ft 60 10ft 120 15ft 180 258 300 50 600 012 003 gal 006 gal 010 gal 016 gal 032 gal A fl oz 8 fl oz 1 2 fl oz 2 0 fl oz 4 1 fl oz 3 028 007 gal 014 gal 022 gal 036 gal 072 gal 9 fl oz 1 8 fl oz 2 8 fl oz 4 6 fl oz 9 2 fl oz 013 gal 025 gal 038 gal 064 gal 127 gal 020 gal 040 gal 060 gal 100 gal 199 gal 029 gal 057 gal 086 gal 143 gal 287 gal 051 gal 102 gal 153 gal 255 gal 510 gal 326floz 653 fl oz VOLUMETRIC CONTENT OF HOSE OR TUBE Metric Units Cross Length Section 76 LN 9240 02 1 Ransburg NOTES LN 9240 02 1 Service Manual Price 50 00 U S Automotive Systems Automotive Finishing Group 48152 West Road Wixom Michigan 48393 Telephone 248 668 8900 Fax 248 668 2160 Order Desk 877 852 7797 Technical Service Assistance 800 626 3565 Industrial Systems Ransburg Electrostatic Systems 320 Phillips Avenue Toledo Ohio 43612 1493 Telephone 419 470 2000 Fax 419 470 2270 Website www ransburg com E Mail marketing ransburg com Order Desk 800 726 8097 Technical Service Assistance 800 233 3366 ISO 9001 Quality Systems
13. inserting a 1 4 inch wrench which may be secured in a vise for this procedure in the hex socket at the rear end of the shaft Secure the nut using the box end wrench LN 9240 02 1 Ransburg gt If the key is not secure or is missing the unit will malfunction 11 With the shaft still secured from rotation screw slinger onto the front end of the shaft and secure it using a spanner wrench NOTE gt Torque the nut to 350 Ib in LN 9240 02 1 Turbodisk 2 Maintenance NOTES 27 Turbodisk 2 Maintenance TROUBLESHOOTING GUIDE Ransburg Fluctuating Pattern Not enough back See regulator manual for diagnosis pressure on regulator Light Coverage on 1 Part hangers hooks are Some Parts not clean Poor Transfer Efficiency 1 Low voltage 2 Disk RPM to high 3 Booth flow to high 4 Diskedge to part distance to great a Clean hangers b Check ground continuity Must be less than 1 Megohm 1 Check disk voltage with H V probe 2 Slow disk speed 3 Reduce booth air flow 4 Decrease conveyor loop diameter Low Current Readings 1 Dirty H V contacts 1 Clean and or replace High Current Readings 1 Target distance to close Power Supply Overloads 2 Conductive paint 3 Fairing dirty 4 H V cable breakdown 5 Fluid tube pinholed to ground on conductive paint systems 6 Isolation mounting rod dirty or carbon tracked Low Voltage 1 Power Supply 2 Faulty H
14. safe operation of electrostatic equipment Operators must read all instructions and safety precautions prior to using this equipment See NFPA 33 Chapter 16 As with any spray finishing system operation of the Turbodisk 2 involves properly setting the operating parameters to obtain the best finish quality for the coating material being sprayed while maintaining correct operation and reliability of the equipment used Adjustments to operating parameters which cover spraying cleaning and on off control include Fluid Type e Fluid Flow Rate Turbine Speed Electrostatic Voltage Target Distance Ransburg COATING MATERIALS The Turbodisk 2 can be used with a broad range of coating material conductivities However with waterborne paints it may be necessary to isolate the paint supply from ground WARNING gt Isolated fluid supplies using either waterborne or highly conductive solvent base coatings can produce hazardous high voltage discharges which can cause fires or injury to personnel FLUID FLOW CONTROL REFER TO FIGURES 19 22 Fluid flow control is dependent on the valve configuration of the Turbodisk 2 If the Turbodisk 2 is configured with no valves or a 3 way valve fluid flow is controlled externally at the paint source If the Turbodisk 2 is equipped with a regulator fluid flow can be controlled via the air pilot signal The high flow and low flow regulators each have procedures on h
15. 0 ER vem 099 8 30 29 mm 22 9 Conical Disk Disk Speed Supply Air Air Flow 1 Air Flow 2 Total Air Flow Total Air Flow EN Pressure PSI SLPM SLPM SLPM EER 12 Conical Disk Disk Speed Supply Air Air Flow 1 Air Flow 2 Total Air Flow Total Air Flow EEN Pressure PSI SLPM SLPM SLPM MESSE Figure 1 Typical Speed Chart 10 Hole Orifice Plate LN 9240 02 1 11 Turbodisk 2 Installation 12 INSTALLATION EQUIPMENT This system should be installed by or under the supervision ofan Ransburg representative Shouldthe needarisetoreplaceany componentassemblywithin the system contact your Ransburg representative This manualconcernsnormaloperation maintenance and service of the specified applicator assemblies The air and fluid connections vary with different models and installations This manual deals primarily with those at or within the assembly AIR CONTROL REFER TO FIGURE 2 Air control of the applicator is from a standard Ransburg air logic panel which includes two filters one 40 micron filter located at the air logic station and one 5 micron filter located at the inlet of the in line air heater panel Clean dry factory air must be provided to the inlet filter of the air logic station via aminimum 1 4 inch I D pipe and to the inlet filter of the heater panel minimum 3 4 inch I D pipe Ransburg MOUNTING REFER TO FIGURE 17 amp 24 The Turbodisk 2 assem
16. 1403 1 8 Hook Assembly Grounding Not Shown Puller Assembly Disk Not Shown LN 9240 02 1 43 Turbodisk 2 Parts Identification Ransburg Figure 15 78718 38 Turbodisk 2 Assembly Trigger amp Dump Valve w DR 1 Fluid Regulator Low Flow Recirculating Fluid Return Dual Fluid Supply System 1 4 I D Tubing Option 44 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78718 38 TURBODISK 2 ASSEMBLY PARTS LIST Figure 15 Assembly Basic Lower Turbodisk 2 Fluid Section 78733 02 gt Assembly Basic Upper Turbodisk 2 Bulkhead andan seg L 3 iting Package Upper Turbodsk2 Bulkhead Val 79725 7 a gee and Dump Valve Assembly we Line Package omn J S rigger and Dump Valve Assembly line Package 78 2292 1 6 Hook Assembly Grounding Not Shown 1594600 1 Puller Assembly Disk Not Shown 19850 00 aa LN 9240 02 1 45 Turbodisk 2 Parts Identification Ransburg Figure 16 78733 Basic Lower Turbodisk 2 Fluid Control Assembly Dual Feed 46 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78733 LOWER TURBODISK 2 FLUID CONTROL ASSEMBLY PARTS LIST Figure 16 ene mL TE ETE MA SE Assembly latching Bulkhead Turbodisk 2 Fluid Section T Includes Following Note Qty is each assembly O Locknut Hex Thin Nylon Insert 10 32 SST Screw Socket Head
17. 38 78175 12 78781 00 19836 02 2 See Parts List Bullet Definition Table on page 37 36 Ransburg Description Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Dual Fluid System Recirculating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Single Fluid System Non Circulating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Single Fluid System Non Circulating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Dual Fluid System Non Circulating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Dual Fluid System Non Circulating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Single Fluid System Recirculating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Single Fluid System Recirculating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Dual Fluid System Recirculating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CCW Dual Fluid System Recirculating Fluid Return 1 4 ID Tubing Option LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification TABLE B Fi
18. 6 MEDIUM 2 BUTANONE MEK Ketones 78 93 3 MEDIUM ISO PROPYL ACETATE Esters 108 21 4 LOW ISOPROPYL ALCOHOL IPA Alcohols 67 63 0 LOW 2 PENTANONE MPK Ketones 107 87 9 MEDIUM METHANOL Methyl Alcohol Alcohols 67 56 1 LOW PROPYL ACETATE n Propyl Acetate Esters 109 60 4 LOW TOLUOL METHYL ISOBUTYL KETONE Toluene MIBK Aromatic Hydrocarbons Ketones 108 88 3 108 10 1 HIGH MEDIUM ISOBUTYL ACETATE Esters 110 19 0 LOW ETHANOL Ethyl Alcohol Alcohols 64 17 5 LOW BUTYL ACETATE Esters 123 86 4 LOW ETHYLBENZENE Aromatic Hydrocarbons 100 41 4 HIGH 1 PROPANOL n Propyl Alcohol Alcohols 71 23 8 LOW 2 BUTANOL sec Butyl Alcohol Alcohols 78 92 2 LOW XYLOL Xylene Aromatic Hydrocarbons 133 02 07 HIGH AMYL ACETATE Esters 628 63 7 MEDIUM 2 METHYLPROPANOL iso Butyl Alcohol Alcohols 78 83 1 LOW METHYL AMYL ACETATE 5 METHYL 2 HEXANONE MIAK Esters Ketones 108 84 9 LOW MEDIUM 1 BUTANOL n Butyl Alcohol Alcohols LOW 2 ETHOXYETHANOL Glycol Ethers LOW 2 HEPTANONE AROMATIC 100 MAK SC 100 Ketones Aromatic Hydrocarbons MEDIUM HIGH DIISOBUTYL KETONE DIBK Ketones MEDIUM 1 PENTANOL Alcohol Alcohols LOW DIACETONE ALCOHOL Keton
19. A WARNING gt Do not hold disk edge during removal This could result in injury LN 9240 02 1 Turbodisk 2 Maintenance Clean the disk by soaking in an appropriate solvent to loosen paint residue Do not soak for more than a 24 hour period Use a soft cloth to remove the paint from the surface and a soft bristle brush to remove paint from the well area The splash plate may need to be removed to clean the paint well The screws must be retorgued to 24 Ib in after cleaning Reinstall the disk and torque the mounting nut to 50 60 Ib in A WARNING gt Do not attempt to clean the disk edge while it is rotating Do not attempt to slow down or stop the disk by holding a rag or a gloved hand against the edge This could cause physical harm and or damage to the disk gt Do not use abrasive materials which will scratch or damage the disk Cleaning pads such as Scotch Brite should not be used gt Using anatomizer disk with paint buildup may cause an imbalance This may result in bearing damage and turbine failure This condition may also stress the disk when operating at high speeds gt Before reinstalling the disk onto the shaft check and clean the tapered mating surface for paint residue gt Care must be taken when mounting the disk assembly to the motor shaft The mounting nut should turn freely for several turns until it fully bottoms on the disk assembly 21 Turbodisk 2 Maintenance VIBRATION NOIS
20. AGE NOTES In the system the high voltage is supplied to the Turbodisk 2 by either the MicroPak Industrial power supply system or Voltage Master series power supplies The MicroPak Industrial power supply uses proven high voltage generator technology that is microprocessor controlled for diagnostics and communication The controller is packaged in standard rack mounted Eurocard format for easy access and system integration The Voltage Master power supplies are general purpose heavy duty power supplies with years of proven reliability They have variable voltage control many safety features and remote analog voltage control capabilities TARGET DISTANCE The distance between the Turbodisk 2 and the target willaffect the finish quality penetration andefficiency Closer distances give wetter finishes and greater efficiency while greater distances give drier finishes The recommended normal disk edge to target range is 12 inches minimum for optimum performance LN 9240 02 1 19 Turbodisk 2 Maintenance MAINTENANCE GENERAL Verify daily that the operating parameters have not varied dramatically A sudden change or even a gradual decay in performance could be early indications of component failure Normal maintenance procedures should be established and recorded at the initial start up All maintenance schedules are subject to variation based on use Periodically review these maintenance schedules as equipment ages and ne
21. BUILD s 22 VALVES amp REGULATORS iiio i ik 22 PREVENTIVE MAINTENANCE aaa 22 DISASSEMBLY PROCEDURES aaa 23 TROUBLESHOOTING GUIDE ee 28 NO VALVE APPLICATION SCHEMATIC 111111 30 3 WAY VALVE APPLICATION SCHEMATIC 31 TRIGGER DUMP w REGULATOR SCHEMATIC 32 TRIGGER DUMP w REGULATOR DR 1 SCHEMATIC 33 CONTINUED ON NEXT PAGE LN 9240 02 1 Turbodisk 2 Contents Ransburg PAGE PARTS IDENTIFICATION 34 69 TURBODISK 2 ASSY MODEL IDENTIFICATION 34 TURBODISK 2 ASSY NO VALVES PARTS LIST 38 TURBODISK 2 ASSY 3 WAY VALVE PARTS LIST 40 TURBODISK 2 ASSY TRIGGER amp DUMP VALVE W FLUID REGULATOR P PARES LIST ait 42 TURBODISK 2 ASSY TRIGGER amp DUMP VALVE W DR 1 FLUID REGU LATOR PARTS LIST aententia 44 LOWER TURBODISK 2 FLUID CONTROL ASSEMBLY PARTS LIST ii 46 UPPER TURBODISK 2 BULKHEAD PLATE amp FAIRING MOUNTING PARTS LIST certiora 48 FLUID SUPPLY LINE PACKAGE PARTS LIST 50 3 WAY VALVE ASSY PARTS LIST 52 HIGH FLOW FLUID REGULATOR ASSY PARTS LIST 54 DR 1 FLUID REGULATOR ASSY PARTS LIST 56 DR 1 FLUID REGULATOR ASSY PARTS LIST 58 TURBODISK 2 AIR HEATER PARTS LIST 60 TURBODISK 2 QUICK RELEASE FAIRING ASSY PARTS
22. Cap 3 8 24 x 1 Long 6 Washer Lock 3 8 Standard Helical Spring 177341212 Screw Socket Head Cap 5 16 24 x 1 Long 8532 32F 6 8 Washer Lock 5 16 Standard Helical Spring 773407 6 3 extension rbd Per S 10 Tube Feed Overhead Installation Down Feed 7097601 2 11 Transmitter Fiber Opti RPM cz 12 Assembly Fiber Optic Cable 47871300 1 13 Screw Set 10 24 x 3 8 Long SSTw NylonTip 54052 1 ong Stent on 2010 3 15 7700 amp 16 Stud AinExtralage 47870800 2 17 O Ring Solvent Proof 5621 0 x 062 Cross Section 556 8165 2 Fitting Mal Comector 3 8 NPT 1 2 O D Tube Size 78168 00 2 19 Cap Identification Green 1 2 O D Tube Size 178169500 2 20 Tubing Nylon Green 1 2 OD x 3 8 LD x 13 Long 78176 01 2 LN 9240 02 1 47 Turbodisk 2 Parts Identification Ransburg Figure 17 78731 Upper Turbodisk 2 Bulkhead Plate and Fairing Mounting 48 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78731 UPPER TURBODISK 2 BULKHEAD PLATE amp FAIRING MOUNTING PARTS LIST Figure 17 Screw Socket Head Cap 3 8 24 x 1 Long 5 Screw Retaining Flange Mount 3 8 16 6 6 Screw Set Hex Socket 10 24x3 8Long SST SSF 2052 1 7 Fitting High Voltage Turbodisk 2 Bulkhead 787040 1 8 Nut Ferrule Nylon 5 820
23. D Tube x 1 4 NPT F SST 10 __ Tubing 4OD x1700D FEP 7669801 11 Nu amp Hex9 61 40D TubeSST E 12 Fernie Back Tube 4 7000001 13 rosa 1 2 3 4 5 7 10 11 12 13 4 LN 9240 02 1 51 Turbodisk 2 Parts Identification Ransburg Figure 19 78723 xx 3 Way Valve Assembly w Fluid amp Air Line Package 52 LN 9240 02 1 Ransburg 78723 xx 3 WAY VALVE ASSY W FLUID amp AIR LINE PACKAGE PARTS LIST Figure 19 1 Assembly Fluid Valve 3 Way RectangularBase 11828302 2 Fitting Street Tee 1 4 NPT Male x 1 4 NPT Female SST LSFI0004 01 1 3 Valve Check 1 4 NPT Male x 1 4 NPT Male SSV 809 1 4 Fitting Female Elbow 1 4 O D Tube x 1 4 557 LSFI0006 01 f 1 5 Tubing 1 4 OD x 170 I D FEP 1 6 Fitting Male Connector 1 4 O D Tube x 1 4 NPT SST 705907 2 Tubing 1 4 x 170 I D FEP 11 8 Fitting Male Elbow 3 8 O D Tube x 1 8 NPT SST f LSFI0007 06 2 9 Fitting Male Elbow Swivel 5 32 O D Tube x 1 8 Brass _____________ 1 1006 1 10 Tubing 5 32 O D x 106 I D N Green Nylon For 78723 01 77536 03 Natural Nylon For 78723 02 77536 05 Cap 5 32 O D Tube po c qc Green Identification For 78723 01 77545 03 2 Natural Identification 78723 02 77545 04 2 s NL tt
24. E If the Turbodisk 2 is vibrating or making an unusual loud noise it may mean that there is an unbalanced situation or a bearing failure The disk could have dried paint or could be damaged This situation should be corrected immediately Do not continue to operate a noisy turbine A WARNING gt Ifadiskhasbeen mishandled orthere appears to be damage on the face DO NOT USE Serious injury can result from rotating a defective disk If there is a concern about the condition of a disk please return it to Ransburg for evaluation TURBINE REPAIR amp REBUILD REFER TO FIGURE 27 Turbine field repair or rebuild only after factory warranty expires Any attempt to disassemble turbine during warranty period will void the warranty VALVES amp REGULATORS REFER TO FIGURES 19 20 21 amp 22 No maintenance is normally required on the valves or regulator other than flushing with solvent daily Visual inspections should be made on the valves and regulator on a weekly basis Should the valve or regulator not function properly refer to the individual manuals for troubleshooting and repair procedures 22 Ransburg PREVENTIVE MAINTENANCE Before any shutdown ormaintenance the fluid system should be thoroughly flushed All cleaning should be done with a minimum of the appropriate clean solvent and clean soft lint free rags or soft brushes where indicated A WARNING gt Do not stop disk rotation by using a rag or gl
25. N 1 2 O D Tube For 78714 01 amp 02 3 8 O D Tube For 78714 03 amp 04 Nut Hex 2221222 7 8 1 2 O D Tube SST For 78714 01 amp 02 11 16 3 8 O D Tube SST For 78714 03 amp 04 70591 03 2 Ferrule Back Tube i 1 2 For 78714 01 amp 02 3 8 For 78714 03 amp 04 L NEUEM Ferrule Front Tube 1 2 For 78714 01 amp 02 70607 05 3 8 For 78714 03 amp 04 Tubing FEP L i 1 2 O D x 3 8 I D For 78714 01 amp 02 3 8 O D x 1 4 I D For 78714 03 amp 04 Fitting Male Connector 1 4 O D Tube x 1 4 NPT 70590 01 PS LN 9240 02 1 55 Turbodisk 2 Parts Identification Ransburg CONNECT TO PTS PAINT 1 SUPPLY LINE DR 1 REGULATED FLUID CONNECT QUE TO FLUID DUMP 1 VALVE 1 DR 1 HIGH FLOW AIR PILOT IN CONNECT TO R1H REGULATOR HIGH AIR LOW Figure 21 78719 xx Fluid Regulator Assembly Low Flow w Fluid amp Air Line Package Non Circulating Fluid Return 56 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78719 xx FLUID REGULATOR ASSY LOW FLOW W FLUID amp AIR LINE PACKAGE Non Circulating PARTS LIST Figure 21 DR 1 Fluid Regulator Assembly Low Flow 2 Stage See Table A Adapter Swivel 1 4 NPSF x 1 4 NPTM SST 101 9120 1
26. SERVICE MANUAL Ransburg a REE Replaces LLN 9240 02 1 January 2013 TURBODISK ASSEMBLY MODELS 78715 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 Turbodisk 2 Contents CONTENTS PAGE SAFETY 1 7 SAFETY PRECAUTIONS ee 1 HAZARDS SAFEGUARDS 2 GENERAL SAFETY GUIDELINES ee ee 5 INTRODUCTION 8 11 Fe 8 GENERAL DESCRIPTION eene rtnn rrnn ret 8 SPECIFICATIONS ct 9 TYPICAL SPEED CHART RPM S oo 10 INSTALLATION 12 15 12 AIR CONTRO ee sha 12 MOUNTING ttti 12 INTERLOCKS ttti 12 TYPICAL TURBODISK 2 DRIVE AIR SYSTEM amp AIR LOGIC CONTROL aci cis ia 13 UPPER TURBODISK 2 BULKHEAD 14 TURBODISK 2 SIGNAL PORT IDENTIFICATION TABLE 15 OPERATION 16 19 COATING MATERIALS ene EE 16 FLUID FLOW CONTROL aaa 16 FLUID VALVE CONTROL 17 FLUID amp AIR PRESSURE REQUIREMENTS 17 TURBINE SPEED 18 ELECTROSTATIC VOLTAGE 19 TARGET DISTANCE ee 19 MAINTENANCE 20 33 GENERA 20 CLEANING PROCEDURES c 20 VIBRATION NOISE been enakan ka iin 22 TURBINE REPAIR amp RE
27. ST always be sure that the high voltage is off the rotator has stopped and that the grounding hook has been properly secured to the motor housing 6 LN 9240 02 1 Ransburg Turbodisk 2 Safety Halogenated Hydrocarbons NOTES A WARNING gt A chemical reaction resulting in the possibility of a pressure EXPLOSION may occur if 1 1 1 Trichloroehtane Methylene Chloride or other Halogenated Hydrocarbon solvents are used in PRESSURIZABLE FLUID SYSTEMS having ALUMINUM or GALVANIZED WETTED PARTS Such an explosion could cause DEATH serious BODILY INJURY and or substantial property damage See Ransburg Bulletins SL 81 05 HHC Explosion Hazard Danger Sign SL 81 08 HHC Explosion Hazard Safety Bulletin Consult your fluid supplier to determine the chemical content of your solvents LN 9240 02 1 7 Turbodisk 2 Introduction INTRODUCTION FEATURES Features which make the Turbodisk 2 Applicator advantageous for use in electrostatic applications include Proven turbine motor reliability Patented serrated edge conical disk provides excellent atomization quality at minimal rotational speeds Aerodynamic fairing design for ease of cleaning of external surfaces Speed readout or control uses reliable magnetic pickup for fiber optic transmission of rotational speed data optional A majority of all assembly components which come in contact with the fluid material are made of either stainless steel or wh
28. V switch or junction tank 3 H V cable 1 Check target distance Ideal target distance is 12 inches minimum 2 Solvent base paint conductivity should be between 05 and 20 megohms on Ransburg paint test meter 3 Clean with nonpolar solvent 4 Replace cable 5 Checktubing routing forareas where fluid tube comes near a ground 6 Clean with nonpolar solvent or replace Use following procedure to isolate problem Verify power supply output Refer to power supply manual for procedure Remove thefairing and measure input voltage to the rotator assembly by removing the H V cable from the connector fitting and inserting it into the H V probe If voltage is low replace H V cable with a known good one and retest If voltage is still low check for bad connections in the H V Junction or Switch Tank Refer to procedures in the proper manual Reinstall the H V cable Check voltage at the rotator housing Figure 6 Troubleshooting Guide 28 LN 9240 02 1 Ransburg Turbodisk 2 Maintenance NOTES LN 9240 02 1 29 Turbodisk 2 Maintenance Ransburg n N Figure 7 Typical No Valve Application Schematic Dual Fluid Supply Option Reference Figure 12 30 LN 9240 02 1 Ransburg Turbodisk 2 Maintenance E me Figure 8 Typical 3 Way Valve Application Schematic Dual Fluid Supply Option Reference Figure 13 LN 9240 02 1 31 Turbodisk 2 Maintenance Ransburg
29. W Single Fluid System 3 8 ID Tubing Option No valves Down Feed CCW Single Fluid System 1 4 ID Tubing Option 78718 04 78175 11 78781 00 19836 02 No valves Down Feed CCW Dual Fluid System 1 4 ID Tubing 3 Way On Off Down Feed CW Single Fluid System 3 8 ID Tub ing Option 3 Way On Off Down Feed CW Single Fluid System 1 4 ID Tub ing Option 78718 13 78175 02 78781 00 19836 01 3 Way On Off Down Feed CW Dual Fluid System 3 8 ID Tub ing Option 78718 03 78175 11 78781 00 19836 02 No valves Down Feed CCW Dual Fluid System 3 8 ID Tubing Option See Parts List Bullet Definition Table on page 37 34 LN 9240 02 1 Ransburg TABLE A Figure 11 Continued Basic Turbine Air Heater amp Disk Turbodisk 2 Air Motor Filter Reg Mounting Dash Assy Assy Assy Nut B 78718 37 78175 02 78781 00 19836 01 24 25 26 27 28 41 42 43 44 45 46 47 48 61 62 63 64 65 67 See Parts List Bullet Definition Table on page 37 LN 9240 02 1 Turbodisk 2 Parts Identification ing Option Tubing Option Tubing Option ing Option ing Option Trigger amp Dump Valve w Fluid Reg High Flow Down Feed CW Single Fluid System 3 8 ID Tubing Option Trigger amp Dump Valve w Fluid Reg High Flow Down Feed CW Single Fluid System 1 4 ID Tubing Option Trigger amp Dump Valve w Fluid Reg High Flow Down Feed CW Dual Fluid System 3 8 ID Tubing Option Trigger amp Dump Valve w Fluid R
30. __ 1352608 1 Flange Support Turbodisk 2 Assembly Includes the Following 7038100 1 Flange Support 7038 00 1 Bulkhead __ 170970 1 Clamp Toe 7037800 2 Screw 5 16 18x1 1 2Long HexHeadCap desease 4 Washer Lock Spring 516 774 4 Screw 1 4 20 x 1 1 2 Long Hex Head Cap 75886 2 Washer Lock Spring 4 027174612271 10 Disposable Cover Turbodisk2Faiming Notshomn InNInN s s nN LN 9240 02 1 49 Turbodisk 2 Parts Identification Ransburg GR P29 OR 52 IN PAINT SOLVENT SUPPLY LINE SUPPLY L 1 T 1 all 35 Figure 18 78732 Fluid Supply Line Package Basic No Valves 50 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78732 FLUID SUPPLY LINE PACKAGE PARTS LIST Figure 18 1 Fitting Fluid Female 3 8 O D Tube Quick Disconnect 7870202 2 Nut Hex 2 __ T 3 femieBakTube38 700663 FeruleFrontTube 3 8 706020 5 Tubing 3 8 O D x 1 4 I D FEP SSP 5020 6 Fitting Male Connector 3 8 O D Tube x 1 4 NPT SST 7 Fitting Street Tee 1 4 M x 1 4 NPT F SST 8 __ Valve Check VANPT M xVANPT M sv 9 Fitting Elbow 1 4 O
31. ations 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 General Use and Improper operation or maintenance Personnel must be given training in accordance with Maintenance may create a hazard requirements of NFPA 33 Chapter 16 2000 edition Personnel must be properly trained Instructions and safety precautions must be read and in the use of this equipment understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping OSHA references are Sections 1910 94 and 1910 107 Also refer to NFPA 33 2000 edition and your insurance company requirements 2 LN 9240 02 1 Ransburg AREA Tells where hazards may occur Electrical Equipment Explosion Hazard Incompatible Materials Toxic Substances LN 9240 02 1 HAZARD Tells what the hazard is High voltage equipment is utilized Arcing in areas 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 shutdown i
32. ay 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 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 Turbodisk 2 Safety AREA Tells where hazards may occur Spray Area High Voltage Equipment Personnel Safety Mechanical Hazards HAZARD Tells what the hazard is 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 The disk atomizer can rotate at speeds up to 40 000 RPM Atthese speeds the edge of the applicator can easily cut into skin Loose articles can also be caught by the rotating disk Ransburg SAFEGUARDS Tells how to avoid the hazard Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must
33. bly 1 With o ring in its groove on the rear face of bearing housing securenozzle plate in place with the six screws NOTE gt Torque the screws to 10 Ib in Do NOT lubricate o ring Using a press tool device on the arbor press table place front bearing over the rear end of shaft Insert the shaft into the press tool rear end down and press the shaft through the bearing until the bearing seats against the shoulder on the shaft Place bearing housing on the arbor press table front face up resting on two parallel supports Insert the bearing shaft into the bore of the bearing housing Witho ringin place against it place bearing retainer over the shaft so that it rests on the bearing Place the press tool large end down over the shaft so that it rests against the bearing retainer Press until the bearing seats in the housing Remove the assembly from the press and secure the retainer with the six screws NOTE gt Torque the screws to 10 Ib in From the rear of the assembly place bearing spacer over the shaft and into the bore so that it seats against the front bearing From the rear of the assembly place spring and spring retainer over the shaft andinto the bore over the bearing spacer In some older models shims and a wave spring washer are used in place of the spring and retainer In those models place shims and wave spring washer over the shaft and into the bore Ransburg 8 With the housing assem
34. bly front face down resting on two parallel supports on the arbor table place the rear bearing over shaft Be sure that o ring is in place in its groove in the housing bore Place the small end of the press tool over the end of the shaft so that it rests against the inner face of the bearing CAREFULLY press the bearing onto the shaft gt Thesamenumberof shims that were removed from the assembly MUST be placed into it or the bearing preload will NOT be correct Each unit is individually preloaded The number of shims used for this purpose may vary from unit to unit It is therefore necessary that the same number of shims be installed in a repaired unit as were removed If morethan one unitis serviced at one time be SUREthat the shims removed from each unit are returned to that same unit 9 With the assembly still on the press table place the turbine rotor flanged side up over the shaft Insert key into the key slot in the shaft align it with the key slotin the rotor and press the rotor down until the key is engaged With the small end of the press tool against the rotor flange press it onto the shaft until it seats gt outer face of the bearing should be a slip fit into the bore of the housing Be careful that the bearing does not hang up on the outer edge of the bore during the pressing 10 Place hex nut and the 15 16 inch box end wrench on the rear end of the shaft Secure the rotating assembly by
35. bly is mounted on the reciprocator using 4 5 16 18 screws provided on the ram flange Loosening 2 1 4 20 screws on the same ram flange will allow the assembly to rotate Position the Turbodisk 2 assembly so that the strain relief boot is positioned toward the incoming fluid and air lines and retighten Remove lowerfairing by releasing the 4 quick release drawlatches Threadallthe required air high voltage fiber optic and fluid service lines through the strain relief boot The strain relief boot may have to be cut largerin orderto feed lines through Refertothe 78718 assembly schematic diagram for connection reference to upper bulkhead plate Reinstall lower fairing Install conical disk and torque to 50 60 Ib in INTERLOCKS Flow of coating material should be locked out unless all of the following conditions are met 1 Booth exhaust is turned 2 The turbine is spinning 3 High voltage is on or in the bypass mode LN 9240 02 1 Ransburg Turbodisk 2 Installation Ah Fe omi vr HOK Eni 6 win 22 18 Hi I Figure 2 Typical Turbodisk 2 Drive Air System and Air Logic Control Panel TYPICAL TURBODISK 2 DRIVE AIR SYSTEM amp AIR LOGIC CONTROL PANEL PARTS LIST Figure 2 Der m eee 781700 Regulator Assembly Drive Ar ncludestheFolowingy 5525439 __ tbowVAODTubexVAWPTWaeSwwd 735 5 8 Regulat
36. d those who operate electrostatic coating equipment Procedures to be followed on conducting electrostatic coating operations safely are outlined in the Ransburg brochure IL 247 Operating Your Electrostatic Coating System Safely Additional copies are available from Ransburg upon request All personnel connected with coating operations should read and understand this brochure It is most important that the equipment operators and supervisory personnel understand the requirements for safe operation WARNING gt If ANY symptom of improper operation occurs suspend use of the unit until the problem has been diagnosed and corrected See the appropriate Troubleshooting Guide or contact your Ransburg representative LN 9240 02 1 Turbodisk 2 Safety Additional cards summarizing these safety require ments are available from Ransburg on request These cards should be posted in the spraying area so that they can be readily referred toand serveas a reminder to personnel in that area of responsibility Additional copies of the sign 51 00 07 Cleaning Safety Require ments are available upon request Each usershould examine his own coating operation develop his own safety program and ensure that his workers follow correct procedures Ransburg hopes that the information it provides is helpful to the user in establishing such a program In addition to the available cards labels brochures and service manuals the user should c
37. e To 1 200 cc min Solvent Base To 1 500 cc min High Solids To 1 000 cc min 80964 Air Inlet Trigger Dump 70 100 psi Air Pilot for Fluid Pressure See Figure 4 Electrical Power Supply MicroPak Industrial or Type Voltage Master Charging Method Direct Input Voltage 0 100 kV Turbine Speed Control or Monitor PulseTrack Optional Turbodisk 2 Introduction Ransburg NOTES TYPICAL SPEED CHART RPM s REFER TO FIGURES 1 amp 23 The following represents data collected under lab conditions Flow meters were installed on each of the two 3 8 I D heated air lines used to supply the Turbodisk 2 turbine motor The airflow through each flow meter was recorded and added together to obtain the total air flow through the system The speed of the disk was monitored through the means of aPulseTrack system The air heater was set at 120 degrees during all data collection Rotational speeds are unloaded and can be expected to drop 20 to 30 when under a fluid load condition Heated turbine air increases efficiency of motor up to 10 This chart should be used as a guide ONLY Speeds will vary due to rotator wear tubing size or lengths etc NOTE gt Never run disk over it s maximum safe operating speed 10 LN 9240 02 1 Ransburg Turbodisk 2 Introduction TYPICAL SPEED CHART 10 HOLE ORIFICE PLATE 6 Conical Disk RPM Pressure PSI SLPM SLPM masm 500 BET EE MO 10
38. e during the warranty period will void the warranty LN 9240 02 1 Ransburg Disassembly REFER TO FIGURE 28 1 After turbine cartridge has been removed from housing secure the rotating assembly by inserting a 1 4 inch wrench which may be secured in a vise for this procedure in the hex socket at the rear end of shaft and remove slinger with a spanner wrench 2 With the 1 4 inch wrench still inserted in the hex socket at the rear end of shaft remove hex nut using a 15 16 inch box end wrench 3 Secure awheel pullertool to turbine rotator Rotate the center screw of the tool until the rotor is free of the shaft Remove key 4 Using 5 64 inch wrench remove the six flat head socket screws which secure bearing retainer to bearing housing Remove the retainer 5 Support bearing housing front face down on two parallel supports on the arbor press table Pressshaftfromthe housing Remove spacer from the shaft gt The space between the supports must be greater than the outside diameter of front bearing 6 On the arbor press table support the assembled shaft bearing frontend down on the two parallel supports With the bearing faces resting on the supports press the shaft free of the bearing 7 Remove rear bearing spring spring retainer wave spring washer and shims in some older models instead of spring and spring retainer and bearing spacer from bearing housing It may be necessary to press the bearin
39. ed determines the quality of atomization and can be varied for different flow rates and viscosities For optimum transfer efficiency and spray pattern control the disk rotational speed should be set at the minimum required speed to achieve proper atomization Excessive speed reduces transfer efficiency A WARNING gt Donot exceed the maximum rated speed of 40 000 RPM forthe 6 inch conical diskand 27 000 RPM for the 6 inch uni disk Ransburg Atomizers REFER TO FIGURE 5 A WARNING gt Never operate any disk atomizer in excess of it s maximum rated speed K number as listed intheservice manual Excessive speed may cause the disk to disintegrate causing serious damage and or injury All atomizers manufactured after April 6 1982 bear a K number That number indicates the maximum saferotation speedforthatseriesintensofthousands For example 9K 9 000 RPM maximum safe speed 40K 40 000 RPM etc If you have an atomizer that does not have a K number contact your Ransburg representative for its maximum safe operating speed TYPICAL MAXIMUM SAFE OPERATING SPEEDS 6 Uni Disk 19830 06 27 000 8 Uni Disk 19830 08 23 000 10 Uni Disk 12 Uni Disk 19830 12 15 000 6 Conical 9 Conical 20485 62 20485 92 25 000 19830 10 15 000 40 000 12 Conical 20485 12x 20 000 Figure 5 Typical Maximum Safe Operating Speeds LN 9240 02 1 Ransburg Turbodisk 2 Operation ELECTROSTATIC VOLT
40. eds change CLEANING PROCEDURES A WARNING gt Electrical shock and fire hazards can exist during maintenance The power supply must be turned off before entering the spray area Spray booth fans should remain on while cleaning with solvents gt Never touch the disk atomizer while it is spinning The edge of the disk can easily cut into humanskin gloves or other materials Be surethe disk atomizer has completely stopped spinning before attempting to touchit Approximate time for the disk to stop spinning after turning off the drive air is about three minutes In addition to the above Warning which relates to potential safety hazards the following information must be observed to prevent damage to the equipment Ransburg gt Do not immerse the Turbodisk 2 assembly in solvent or other liquids Turbine components will be damaged gt Do not soak the disk in solvent longer than 24 hours Internal Fluid Path Cleaning With the high voltageturned offand the diskspinning flush cleaning solvent through the incoming paint line or through the solvent inlet line If it is desired to clean just the face of the disk off flush solvent through the solvent inlet If a color change is required flush the entire system The spinning disk will atomize the solvent and clean out the disk passages If equipped trigger the dump valve to catch the wasted paint from the incoming line then flush the disk with solvent after clos
41. eg High Flow Down Feed CW Dual Fluid System 1 4 ID Tubing Option CCW Single Fluid System 3 8 ID Tubing Option CCW Single Fluid System 1 4 ID Tubing Option CCW Dual Fluid System 3 8 ID Tubing Option CCW Dual Fluid System 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Single Fluid System Non Circulating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Single Fluid System Non Circulating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Dual Fluid System Non Circulating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Dual Fluid System Non Circulating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Single Fluid System Recirculating Fluid Return 3 8 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Single Fluid System Recirculating Fluid Return 1 4 ID Tubing Option Trigger amp Dump Valve w DR 1 Fluid Reg Low Flow Down Feed CW Dual Fluid System Recirculating Fluid Return 3 8 ID Tubing Option 35 Turbodisk 2 Parts Identification TABLE A Figure 11 Continued Basic Turbine Air Heater amp Disk Turbodisk 2 Air Motor Filter Reg Mounting Assy Assy gt 78718
42. eration or when high voltage is supplied to the applicator Paint Valve Options Four paint valve options in single or dual feed applications are available No Valves refer to Figures 7 12 18 3 Way On Off Valve refer to Figures 8 13 19 Trigger and Dump Valve with High Flow Regulator refer to Figures 9 14 20 25 Trigger and Dump Valve with Low Flow Regulator refer to Figures 10 15 21 22 25 Power Supply and Controls In the system the high voltage is supplied to the Turbodisk 2 by either the MicroPak Industrial power supply system or a Voltage Master series power supply The MicroPak Industrial power supply uses proven high voltage generator technology that is microprocessor controlled for diagnostics and communication The controller is packaged in standard rack mounted Eurocard format for easy access and system integration The Voltage Master power supplies are general purpose heavy duty power supplies with years of proven reliability They have variable voltage control many safety features and remote analog voltage control capabilities LN 9240 02 1 Turbine Speed Variable to 40 000 rpm max 6 conical disk Turbine Type Ball Bearing Weight 57 Ibs approximately Length in Diameter 1325 Turbine Air At max speed 40krpm requires 103 1 psi and 61 1 scfm unloaded see Figure 1 Fluid Pressure Inlet See Figure 4 Single Fluid Flow Range Waterborn
43. es LOW 2 BUTOXYETHANOL Butyl Cellosolve Glycol Ethers LOW CYCLOHEXANOL Alcohols LOW AROMATIC 150 SC 150 Aromatic Hydrocarbons HIGH AROMATIC 200 CAS Number Chemical Abstract Service Number Using the Ransburg Meter Solvent Base Configuration Only Information Obtained From http solvdb ncms org Evaporation Rate is Based Upon Butyl Acetate Having a Rate of 1 0 NOTE our electrostatic equipment LN 9240 02 1 Aromatic Hydrocarbons HIGH 92000 Ransburg This page provides resistivity determination and control information that we feel is necessary when using Ransburg Turbodisk 2 Appendix T o o x oo en oO CN CN j e jeje e m m NININA om M e T O m IN I MIOININI gdnoug l III A T O F TN TOON NM j INTMITINIO In O in O in O NININI NINI N MI n T T al a c el o leo alm NX HUN sqasy JIudeibouu Jaupsey ajgang Tale BE BE lt lt lt _ r gt gt 7 RAET ili y An L IT TRETT an p104 TI a
44. g from the housing using a wood or plastic rod or tool handle inserted through the bore from the front LN 9240 02 1 Turbodisk 2 Maintenance gt Never use a tool that is harder than the part it is used on 8 With a 5 64 inch wrench remove the six flat head socket screws from nozzle plate Remove the nozzle plate 9 Remove all o rings Inspection and Preparation gt Failure to observe the following cautions will resultin diminished performance and premature motor failure Never use any silicone compound in this system Never use any lubrication on the bearings Never use any solvent on the bearings Never exert force on one race ofa bearing assembly that may be transmitted to the other race through the bearings Force and resistance must always be on the same race in order to prevent damage Donotenlargethe nozzle passages during cleaning as it will effect performance Always observe the specified torque in tightening fasteners Clean all parts thoroughly with an appropriate clean solvent Inspect them for wear or damage and replace as required Checkallflow passages for obstruction particularly the nozzle plate Clear as required Discard all bearings and o rings and replace with new Lightly lubricate o rings with petroleum jelly before assembly Fit parts with o rings very carefully They must not be allowed to distort unseat or break 25 Turbodisk 2 Maintenance 26 Assem
45. gure 11 oe Non Circulating Fluid Return DRA Dual Fluid System me 7879383 08 Non Circulating Fluid Return DR Dual FluidSystem 18 7871904824 09 Non Circulating Fluid Return DRA Single Fluid System w0 787905 Recirculating Fluid Return DR 1 Dual Fluid System 78719 51 amp 71 PARTS LIST BULLET DEFINITION TABLE Figure 11 1 General Application Guideline Use for fluid flow rates above 750 ml min gt General Guideline Use for fluid flow rates from 25 to 1500 ml min Note Assemblies using DR 1 fluid regulators part number 74151 xx 1 Disk mounting nut see Table A is included with this assembly When installing disk not included torque mounting nut to 50 60 Ib in Recommended 3 8 hex bit socket with square drive torque wrench DR 1 Non circulating fluid return applies see Table B DR 1 Recirculating fluid return applies see Table B LN 9240 02 1 37 Turbodisk 2 Parts Identification Ransburg PEE T ME JER Figure 12 78718 04 Turbodisk 2 Assembly No Valves Dual Fluid Supply System 1 4 I D Tubing Option 38 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78718 04 TURBODISK 2 ASSEMBLY PARTS LIST Figure 12 Assembly Basic Lower Turbodisk 2 Fluid Section 78733 02 Assembly Basic Upper Turbodisk 2 Bulkhead and Fairing 78731 01 itting Package Upper Turbodisk 2 Bulkhead 1 4 I D 78729 04 7 Hoo
46. gure 24 LL gr T Serew 174 20 3 4 Long Nylon HexHeed 6 Screw 5 16 24 x 1 Long Hex Head tock washer steier fm 2 Screw 1 4 20 x 1 2 Long Hex Head 795816C 6 8 tockwasher ammon 777608 6 gt E LEDE T Boot Stain Rel fv EO Plug Machined Feed Tube Adjustment 7090909 15 Shroud Machined EE BES EE 15 Screw 86332 172 Long Nylon Fat eat ia TE 56 Wut 6632 Nylon Hex i7 Shroud Disposable Cover Not Shown eo gt gt LN 9240 02 1 63 Turbodisk 2 Parts Identification Ransburg Figure 25 78722 xx 2 Valve Assembly Trigger amp Dump 64 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78722 xx 2 VALVE ASSEMBLY TRIGGER amp DUMP PARTS LIST Figure 25 1 Bracket Fluid Valve Mounting 78120 O 2 Fitting Male Elbow 1 2 O D Tube x 1 4 NPT SST 7776703 1 Adapter Turbodisk 2 Dump Valve mo 4 FluidValve Assembly 5 2 5 Pipe Nipple 1 4 18NPTx7 8Long 5 45 1 6 Fitting Male Connector 5 32 O D Tubex1 8NPT 2 Cap 5 32 O D Tube ns Red Identification For 78722 01 Black Identification For 78722 02 Tubing 5 32 x 106 I D Red Nylon For 78722 01 Black Nylon For 78722 02 Cap 5 32 O D Tube
47. ible to re orient the fluid valving so that the exhaust adapter is not required LN 9240 02 1 69 Turbodisk 2 Parts Identification Ransburg C W ROTATION gt 7 JE E r C C W ROTATION a AN TORQUE TO S Z NX 350 LBS IN X N ee 2 2 a k s _ gt ed a Lom E x m 2 qu ud ga a BEARING PRELOAD ZN REF aa T 30 LBS REF Er f zd ae i I S Z eye 3 7 2 TORQUE TO 10 LBS IN Figure 28 70879 xxx Turbodisk 2 Turbine Cartridge Assembly 70 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 70879 xxx TURBODISK 2 TURBINE CARTRIDGE ASSEMBLY PARTS LIST LEE 28 hem pea gt 1 RetinenBeaing 17087300 1 6 ono BEER 1 8 DeaiXusPxeubodk s Key Woodruff ac 0 Nut Seth Lock 578 18 UNF ms 7 Housing Bearing Machined 16 FN a my 18 Shaft Air Motor ___ lt PG See corresponding column in Table A TABLE A Figure 28 m meme TA Toe LN 9240 02 1 71 Turbodisk 2 Warranty Policies 72 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 p
48. ich is impervious to most fluids Negligible maintenance down time With the quick disconnect feature the lower Turbodisk 2 fluid section can be exchanged in minimal time for off line maintenance Quick disconnect feature allows for other fluid control assemblies to be incorporated when desired The easily removable lower fairing turbine air motor assembly and the externally mounted regulators and fluid valves make off line maintenance more efficient and economical Control air lines are color coded for ease of identification Higher fluid delivery rates can be achieved using a dual feed fluid system High flow regulators and fluid valves provide for simultaneous paint push out while solvent washes the feed tube and disk Ransburg GENERAL DESCRIPTION The Turbodisk 2 Applicator because of it s high rotational speed produces finer atomization improved quality and higher transfer efficiency with any of the wide variety of coating materials such as waterborne and high solids used in production finishing operations It s speedis controlled by varying the drive air The applicator assembly is designed for use on vertical overhead mounted reciprocators Quick Disconnect REFER TO FIGURES 16 17 amp 26 The Turbodisk 2 Applicator is a quick disconnect design that allows the lower fluid section that carries all the fluid air controls to be separated from the upper section carrying the tubing supply lines The incom
49. ing air lines fluid lines high voltage cable and fiber optic cable are connected to the fittings provided on the upper fixed bulkhead plate Each bulkhead plate upper and lower utilizes special male and female fittings with o rings that seal the fluid and air line passages when both sections are assembled together Two latching mechanisms have been incorporated into the design allowing the lower section to be supported while the operator tightens or loosens the retaining screws that hold the upper and lower sections together Alignment arrows engraved into the side of the bulkhead plates provide for quick visual assembly orientation Conical Disk Assembly The Turbodisk 2 Applicator uses conical disk assemblies that are made from high grade aluminum construction and are force balanced 10 grams in or better With the patented serrated edge these disks come in sizes of 6 9 and 12 inch diameters LN 9240 02 1 Turbodisk 2 Introduction Ransburg Turbodisk 2 Fairing REFER TO FIGURE 24 SPECIFICATIONS The Turbodisk 2 Applicator fairing is required for Mechanical safe operation The two piece fairing provides high voltage isolation from the metal rotator assembly and valve components as well as ease of cleaning and maintenance Provided on the fairing are 4 draw latches which allow for easy on off removal of the lower fairing WARNING gt Both sections of the fairing to be in place when the Turbodisk 2 is in op
50. ing the dump valve NOTE gt Solvent flushing of the system except during color change should be done with the disk dismounted and with waste solvent collected in a grounded container LN 9240 02 1 Ransburg External Atomizer Surface Cleaning A WARNING gt To reduce the risk of fire or explosion OSHA and NFPA 33 require that solvents used for exterior cleaning including disk cleaning and soaking be nonflammable flash points higher than 100 F 37 8 C Since electrostatic equipment is involved these solvents should also be nonpolar Examples of nonflammable nonpolar solvents for cleaning are Amylacetate methyl amyl acetate high flash naphtha and mineral spirits gt Donot use conductive solvents such as MEKto clean the external surfaces of the Turbodisk 2 gt Never lower the Turbodisk 2 assembly into a drum for flushing or color changing Disk Cleaning Normally the internal cleaning instructions will suffice to clean the disk If flushing the disk does not remove all the residue the disk may be removed for hand cleaning Unscrew mounting nut and remove the disk by using the supplied disk puller Inspection of the disk is required to determine if wear to the serrated edge or damage has occurred Wear can cause a reduction in transfer efficiency and excessive paint wrap on the atomizer fairing NOTE gt The turbine shaft must be held with a 7 16 open end wrench while using the disk puller
51. k Assembly Grounding Not Shown 15946 00 F D Fluid Supply Line Package Lower Turbodisk 2 No Valves 8732 01 Puller Assembly Disk Not Shown 19850 00 LN 9240 02 1 89 Turbodisk 2 Parts Identification Ransburg saia r Figure 13 78718 14 Turbodisk 2 Assembly 3 Way Valve On Off Dual Fluid Supply System 1 4 I D Tubing Option 40 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78718 14 TURBODISK 2 ASSEMBLY PARTS LIST Figure 13 Assembly Basic Lower Turbodisk 2 Fluid Section 78733 02 gt Assembly Basic Upper Turbodisk 2 Bulkhead andan vars 3 Package Upper Turbodisk2 Bulkhead iD 4 Assembly 3 Way Valve Line Package 1 Feed ese J 5 Assembly 3 Way Valve w Fuid Line Package Ped ge 6 Hook Assembly Grounding Not Shown 15946 00 1 Puller Assembly Disk Not Shown 19850 00 aa LN 9240 02 1 41 Turbodisk 2 Parts Identification Ransburg Figure 14 78718 24 Turbodisk 2 Assembly Trigger amp Dump Valve w Fluid Regulator High Flow Dual Fluid Supply System 1 4 I D Tubing Option 42 LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78718 24 TURBODISK 2 ASSEMBLY PARTS LIST Figure 14 Assembly Basic Lower Turbodisk 2 Fluid Section 78733 02 Assembly Basic Upper Turbodisk 2 Bulkhead and Fairing 78731 01 6 1 Fluid Regulator Assembly High Flow w Fluid Line Package 787
52. lay Verify with high voltage probe and meter Remove fairing and clean all internal components valves regulators and tubing Check tubing for evidence of pin holes kinks and abrasions If the muffler needs to cleaned item is to be solvent cleaned remove it from the motor Clean and dry the muffler before reinstalling it Check fluid flows by removing the diskand manually triggering the paint valve Measure the amount of fluid in a graduated beaker over a specific time to determine flow rate Clean andinspectthe disk face Look for wear which can cause poor transfer efficiency and excessive paint wrap on the atomizer fairing Disk removal cleaning and inspection may be done more or less frequently depending upon use LN 9240 02 1 Turbodisk 2 Maintenance DISASSEMBLY PROCEDURES Prior to disassembly verify the following The atomizer disk valves and regulator have ben flushed with solvent and purged dry with air The disk has stopped rotating The air supply to the trigger valves and regulator have been turned off The fluid and solvent supply have been turned off and the pressure has been relieved The high voltage has been turned off and the motor housing grounded Turbine Cartridge Exchange REFER TO FIGURE 27 Removal 1 Remove disk mounting nut by holding the rotator shaftabove thediskwitha 7 16 open end wrench and unscrewing the mounting nut with 3 8 inch wrench 2 Instal
53. lthe Ransburg 19850 00 disk pullerinto disk to remove it 3 Unlatch the four fairing draw latches and carefully remove lower fairing 4 The lower fluid section of the Turbodisk 2 Applicator containing the turbine cartridge may now be disconnected for continued off line removal procedures through means of the quick disconnect feature incorporated into the unit WARNING gt Handlethe disk with caution The sharp edge can cut even though it is not rotating 23 Turbodisk 2 Maintenance With a 5 16 inch wrench loosen the six captive retaining screws used to hold the upper and lower sections together Note As the last screw releases the lower unit will drop only enough to allow for the bulkhead plates to be separated The two latching mechanisms on the bulkhead plates will hold the unit in place until the operator is ready to move the lower section to a proper work place 5 Once the lower fluid section is placed in a stationary condition the removal of the cartridge can be continued 6 Next remove screws holding the fluid tube assembly 7 With a 7 64 inch wrench remove six socket head cap screws which secures the turbine cartridge to the motor housing 8 Using a 1 16 inch wrench turn each of the three jack screws located next to socket head cap screw clockwise not more than one half turn at a time in sequence to separate the motor from the housing gt Failure to perform this step correctly ma
54. ment is in operation See NFPA Bulletin No 33 Personnel All personnel should read and understand local codes appropriate NFPA bulletins OSHA Act of 1970 and this service manual Personnel working in the spray area MUST be adequately grounded Insulated shoes such as Housekeeping rubber composition or cork soles should NOT Good housekeeping is essential to safe operation be worn unless an alternate grounding method Clean up and maintenance schedules should be is provided See Ransburg Bulletin SL 77 01 established by the user based on observations of Personnel Grounding theinitial production operations Maintenance and safety cards should be posted in clear view of the operator A WARNING Normal fire protection measures are required gt ALWAYS turn power supply OFF prior to These include proper storage of paints solvents cleaning or working on equipment and waste plus ready access to fire extinguishing equipment For details consult NFPA Bulletins No gt ENSURE that the grounding hook has been 30 33 70 and 77 your local fire codes local paint properly secured to the motor housing equipment standards OSHA Act of 1970 and your insurance carrier s recommendations Floor Covering and Masking If it is necessary to cover booth flooring Ransburg suggests that the user employ a material which will NOT support combustion such as Spark Gard Grade BWA 100 Personnel working on applicators MU
55. ndicates a problem in the system which requires correction An electrical 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 Certain material may be harmful if inhaled or if there is contact with the skin Turbodisk 2 Safety SAFEGUARDS Tells how to avoid the hazard The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Refer to NFPA No 33 2000 Edition 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 shouldnever be done with the safety circuits disabled Beforeturningthehigh 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 spr
56. not exceed 1 megohm Allelectrically conductive objects inthe spray area with the exception of those objects required by the process to be at high voltage must be grounded Any person working in the spray area must be grounded Unless specifically approved for use in hazardous locations the power supply and other electrical control equipment must not be used in Class 1 Division 1 or 2 locations Personnel must stay clear of the disk whenever it is rotating Before touching the disk the turbine air must be shut off Ifthe disk has been rotating allow atleast three minutes for it to come to a complete stop before touching it LN 9240 02 1 Ransburg GENERAL SAFETY GUIDELINES The articles being coated MUST be grounded at all times A WARNING gt The simple safety measures outlined here are vital Failure to observe them could cause a spark capable of starting a fire Allcomponents of the applicator system except the atomizing head MUST be grounded at all times Allcontact points MUST be free ofany accumulation of nonconductive residue Allelectrically conductive objects especially solvent containers within the spray area MUST be either removed or grounded Any tool if used improperly can be dangerous Safety is ultimately the responsibility of those using a tool In like manner safe operation of electrostatic coat ing processes is the responsibility of those who use such processes an
57. onsult other standards and recognized safety authorities Section 1910 107 of the regulations established under the Occupational Safety and Health Act OSHA apply to spray finishing operations Paragraph i specifically applies to electrostatic hand spraying equipment NFPA No 33 Spray Application is another standard for spray painting operations Chapters 9 10 and 13 are specifically applicable to electrostatic coat ing Copies of NFPA No 33 are available from the National Fire Protection Association Batterymarch Park Quincy Mass 02269 at nominal cost The National Fire Protection Association also pub lishes standards other than NFPA No 33 relating to the control of fire hazards NFPA No 33 specifically refers to the following bulletins of the National Fire Protection Association as applicable to coating op erations NFPA No 63 Dust Explosion Industrial Plants NFPA No 70 National Electrical Code NFPA No 86A Ovens and Furnaces NFPA No 91 Blower and Exhaust Systems NFPA No 654 Dust Explosions Plastics Industry NFPA No 77 Static Electricity also contains much useful information Copies of these brochures will be helpful in arriving at a program for safe operation Local codes and authorities also have standards to be followed in the operation of your spray equipment Your insurance carrier will be helpful in answering questions that arise in your development of spray coating procedures Turbodisk 2 Safe
58. or V2NPTPored ATFioted 4 781516 __ Nipple VINPTKTSlongBasPipe 1 150187 Regulator 1 Ported Manual A I T NETX 5 Brass BESTE Gauge 0 160 psig VANPLAT GET Nipple T RPT x 3 NPT Hex 78166 00 66 00 Hose AaB Compressed Air Includes the Following 64 00 Hose 3 4 I D Push Loc Air Fitting Female SAE 45 Swivel x 3 4 I D Hose Tubing 1 2 x 375 I D Green Nylon To Suit waar LN 9240 02 1 13 Un Turbodisk 2 Installation Ransburg Figure 3a Upper Turbodisk 2 Bulkhead Plate Reference Figure 26 14 LN 9240 02 1 Ransburg Turbodisk 2 Installation TURBODISK 2 SIGNAL PORT IDENTIFICATION TABLE Figure 3b on Bulkhead Pip __ mea Rx me Figure 3b Turbodisk 2 Signal Port Identification Table LN 9240 02 1 15 Turbodisk 2 Operation OPERATION gt Fluids and lubricants used in this system must contain NO silicones gt DoNOT operate the unit without an atomizer disk Without a disk overspeed resulting in premature bearing failure is possible gt The air supplied to the motor must be dry clean and free of oil or moisture The atmospheric dew point should be 10 F or less The air heater used should be adjusted only high enough to preventcondensation fromforming onthe motor housing or at the exhaust port A WARNING gt Operators must be fully trained in
59. oved hand gt Make sure high voltage is off before approaching applicator gt Follow proper grounding procedures gt Because ofthe hazard of bearing penetration solvents should be used sparingly They should never be hosed directly onto the atomizer motor housing or fiber optic juncture Daily Maintenance A WARNING gt Personnel working on applicators MUST always be sure that the high voltage is off the fluid system is flushed and off the rotator has stopped and that the grounding hook has been properly secured to the motor housing Clean the atomizer disk motor housing fairing and as needed the peripheral equipment with nonpolar high flash point solvents LN 9240 02 1 Ransburg Topreventsolvent penetration beyond theslinger a minimal air pressure of 5to 10 psishould beapplied tothe motor in orderto maintain a positive pressure The motor should be run at operating speed for several minutes after cleaning to keep any solvent that has accumulated at the seals from penetrating into the motor housing Inspectthe disk edge and face If damageexists DO NOT USE Return it to Ransburg for evaluation Check the fluid feed tube to make sure it is not rubbing the disk Weekly Maintenance Follow the normal daily maintenance schedule then Monitor rotational speed at the control and verify it is within 5 of target speed Monitor high voltage output indicated onthe power supply disp
60. ow to control and deliver consistent fluid flows For moreinformation on controlling the fluid delivery using regulators refer to that specific manual which is included with the system To check fluid flow rates the disk must be removed See the maintenance section for removal procedure The fluid can then be manually triggered to measure actual flow in a graduated beaker over a specified time period A WARNING gt Danger of shock and or personal injury can occur Proper grounding procedures which are outlined in the Ransburg safety bulletins must be followed Personnel must never work near or perform work on the turbine when the turbine is spinning or when high voltage is on LN 9240 02 1 Ransburg FLUID VALVE CONTROL Trigger and Dump REFER TO FIGURES 4 amp 25 The fluid valves in the Turbodisk 2 are actuated by an air signal The air pressure must exceed 70 psito assure properactuation of the valve Applying air to the valve actuator turns on the fluid flow for that valve The trigger valve controls the paint flow to the disk When actuated paint flows through the valve to the fluid tube The disk should be spinning at a RPM speed that is fast enough that when fluid is turned on to enable the fluid to flow through the disk paint passage holes and be atomized The dump valve controls the paint flow through the dumpline When actuated paint flow is directed tothe dump return line This provides a method of ra
61. pidly removing paint from the incoming line for cleaning No Valves 78718 01 thru 10 Air Pilot Fluid Solvent Inlet 3 Way ON OFF 18283 78718 11 thru 20 Turbodisk 2 Operation and or color change Normally the dump valve is not actuated at the same time as the paint trigger valve since the trigger valve is intended to cause the fluid flow to the disk at the prescribed input pressure FLUID amp AIR PRESSURE REQUIREMENTS REFER TO FIGURE 4 Fluid and air pressure requirements are dependent on the fluid trigger valve configuration Trigger Dump w High Flow 70171 04 Regulator Trigger Dump w Low Flow DR 1 74151 Regulator 78718 21 thru 30 78718 31 thru xx 120 psi max 70 100 psi 70 100 psi 300 psi max 80 100 psi max 80 100 psi max L 30 60 psi max 30 60 psi max 30 60 psi max Note Trigger dump valves CCV 403 SS are rated to 300 psi maximum inlet fluid pressure but are limited to the lower pressure limit of the fluid regulators Figure 4 Turbodisk 2 Fluid amp Air Pressure Requirements LN 9240 02 1 17 Turbodisk 2 Operation TURBINE SPEED Turbine speed is determined by the drive air pressure at the rotary atomizer and fluid flow rate Turbine speed can be closed loop controlled using the fiber optic speed transmitter mounted at the back of the turbine rotator assembly as a speed input to remote speed controls such as the PulseTrack NOTE gt The disk rotational spe
62. quipment 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 providea 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 LN 9240 02 1 Turbodisk 2 Safety A WARNING gt 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 betaken toensure thatthe WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of andadhere to ALL local building and fire codes and ordinances as well as 33 SAFETY STANDARD 2000 EDITION prior to installing operating and or servicing this equipment A WARNING gt Thehazardsshown onthe following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 Turbodisk 2 Safety Ransburg
63. rovided 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 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 ASSOCIATEDVALVES ANDTUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY FLUID HANDLING One 1 year from date of purchase i e Totalizer CCV Valves etc AIR BEARING ROTATORS Fifteen thousand 15 000 hours or three 3 years whichever occurs first Warranty period begins on the date of purchase RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THERE ARE NO IMPLIED WARRANTIES NORWARRANTIES OF EITHER MERCHANTABILITY OR Ransburg FITNESS FOR A PARTICULAR PURPOSE RANSBURG ASSUMES NO LIABILITY FOR INJURY DAMAGE TO PROPERTY OR FOR CONSEQUENTIAL DAMAGES FOR LOSS OF GOODWILL OR PRODUCTION OR INCOME WHICH RESULT FROM USE OR MISUSE OF THE EQUIPMENT BY PURCHASER OR OTHERS
64. ty Ransburg All personnel MUST read and understand the Parts following Ransburg Safety Publications Articles being painted MUST be grounded at ALL times Paint MUST NEVER be permitted to IL 247 Operating Your Electrostatic Coating System accumulate on workholders particularly on points Safely SL 77 01 Personnel Grounding where workholders touch conveyor Hooks MUST be clean to ensure proper contact Itis advisable to Ransburg also suggests that all personnel read the have extra sets of workholders to enable cleaning of HEW publication Spray Painting Good Practices for the sets not being used at regular intervals Areas Employees number NIOSH 78 178 available from the regional NIOSH office or the U S Government Printing Office of hanger contact should be sharp points or edges where possible All electrically conductive objects within the spray area including spray booth paint tank and conveyor MUST BEGROUNDED This requirement applies to the solvent safety container paint containers wash cans and all other objects in the area NIOSH and OSHA regional offices can provide information on OCCUPATIONAL SAFETY AND HEALTH ACT including questions on standards interpretations voluntary compliance information copies of the OSHA Standards OSHA Act Employee Rights Posting Notice and Publications Ventilation We recommend interlocking the ventilation with the spraying equipment to ensure proper ventilation when equip
65. urbodisk 2 Air Turbine Assembly 68 Ransburg LN 9240 02 1 Ransburg Turbodisk 2 Parts Identification 78175 xx TURBODISK 2 AIR TURBINE ASSEMBLY PARTS LIST Figure 27 1 Housing Assembly Machined Turbodisk2 Upgrade 78174400 1 gt Screw 8 32x5 16Long Slotted Round Head e 3 iekWaserfHelalsping pa Plug Protective fm TT 5 pwuflesrNPTPoyeHeneEduus 4 5 Fitting Machined Exhaust Adapter Identification Cap 1 2 O D Tube Green 8 Fitting 1 2 NPT x 1 2 OD Tube SR 423910 x 070 cs Solvent Resistant fs 4 AirMotor Assembly Turbodiska 712 screw 6 32x 172 Long Socket Head Gap Vimse is Nameplate Turbodisk2 See corresponding column in Table A TABLE A 27 00 2 78175 01 Air Motor Assembly CW Rotation w o Exhaust Adapter o 70879406 E E se Ca TTC RN 5 dm 7817511 Air Motor Assembly CCW Rotation w o Exhaust Adapter o 70975456 787512 Air Motor Assembly CCW Rotation w Exhaust Adapter 1 70879456 M See Parts List Bullet Definition Table PARTS LIST BULLET DEFINITION TABLE Figure 27 The exhaust adapter is required only when the orientation of the fluid valving will not allow the exhaust muf fler to be installed directly into the turbine housing If the installed system provides an interference then it may be poss
66. y result in misalignment and possible damage Usecautionin removing cartridgeto prevent it from falling out of the housing Ransburg Installation Always check the inside of the motor housing and clean if required with a minimum amount of an appropriate cleaning solvent and a soft cloth 18 Using 1 16 inch wrench retract the three jack screws gt Lightly lubricate o rings with petroleum jelly before assembly Fit parts with o rings very carefully They must not be allowed to distort unseat or break 2 With o rings in place on the nozzle plate and housing insert the turbine cartridge into motor housing 3 Secure the rotator assembly to the housing with six socket head cap screws Tighten the screws in sequence until the cartridge is fully engaged into the housing to prevent misalignment and possible damage Torque to 10 Ib in 4 To avoid losing the jack screws during normal operation torque to 2 3 Ib in Turbine Cartridge Service This cartridge is a precision instrument and should be handled with care The bearings are preloaded to 30 pounds and dynamically balanced to 0 01 gramsein or better NOTE gt Bearings used in this cartridge contain special grease that is available exclusively to Ransburg The purchase of replacement bear ings from sources other than Ransburg is not recommended Turbine field repair or rebuild ONLY after factory warranty expires Any attempt to disassemble turbin

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