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TURBODISK ™ APPLICATOR ASSEMBLY

1. 69 TOOLS AND ACCESSORIES 70 WARRANTY POLICIES 71 LIMITED WARRANT Y 71 Ransburg Turbodisk Applicator Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand Thisinformation relatesto 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 equipment Differences in local codes and plant requirements material delivery requirements etc make such variations inevitable Compare this manual with your system installation drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful
2. gt 2 8156 24F Screw 5 16 24 X 3 4 Hex Head 8156 24 8156 32F Screw 5 16 24 X 1 Hex Head 8156 40F Screw 5 16 24 X 1 1 4 Heax Head L Washer Spring 5 16 High Voltage Connector Assembly Extension Arm Air Motor 2 10 Tube Support 20 3 8 2 1 2 2 2 3 2 4 2 5 2 9 2 11 8156 48F Screw 5 16 24 X 1 1 2 Hex Head Not Used 2 13 27141 081 Hose Wrapping Not Shown Same as TR SSEM 082 2 14 15946 00 Grounding Hook Assembly Not Shown 2 15 10384 01 Tubing Latex 3 16 ID X 1 16 Wall Not Shown 50 These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly Tubing LD PE 1 4 OD X 17 ID 7113 13 Tubing 1 2 OD X 060 Wall Nylon 50 Tubing 3 8 OD X 1 4 ID ET with Kit 70977 04 only Tubing 1 2 OD X 3 8 ID Supplied with Kit 70977 05 only Elbow 3 8 OD Tube X 1 4 NPT Supplied with Kit 70977 04 15 0005 01 Connector Straight 1 2 OD Tube X 1 4 upplied with Kit 70977 05 1 FTC 1002 Connector Straight 3 8 OD Tube X 1 4 3 1 3 2 3 3 3 3 3 4 3 4 3 5 These parts are supplied with Kit 70975 10 Trigger Valve Kit 70590 01 Male 1 4 OD Tube X 1 4 SS LRPM0105 CCV 12 SS Valve Adapter LDSK4000 2 Valve Assembly Trigger and Dump SSP 6054 Connector 1 4 OD Tube X 1 8 Male Brass 55994 23 Tubing
3. 70977 05 70977 06 Tube 1 2 OD Tube 1 4 OD 18283 02 Valve Assembly 3 Way Select Option Below Fluid jusror bRimegdworrzao 7415107 DRT Regulatort Ratio Cd 7415103 DRiReguatoriGRaio O T r 7415104 DRT Regulatort Rato T rT 74151 05 74151 06 74151 11 DR 1 Regulator T 70 Ratio DR 1 Regulator 1 3 Ratio DR 1 Regulator 1 1 Ratio 70171 04 High Flow Fluid Regulator Select Option Below Disk 20485 62 Disk Assembly Serrated 6 Aluminum Not Anodized 20485 65 20485 92 20485 95 20485 122 20485 125 19830 06 19830 08 19830 10 19830 12 Select Option Below 70879 406 70879 456 Select Option Below 70976 01 70986 02 70986 03 69 Disk Assembly Serrated 6 Aluminum Anodized Disk Assembly Serrated 9 Aluminum Not Anodized Disk Assembly Serrated 9 Aluminum Anodized 0 1 Disk Assembly Serrated 12 Aluminum Not Anodized Disk Assembly Serrated 12 Aluminum Anodized Uni Disk Assembly Aluminum Not Anodized Uni Disk Assembly 8 Aluminum Not Anodized Uni Disk Assembly 10 Aluminum Not Anodized Uni Disk Assembly 12 Aluminum Not Anodized Disk Motor Air Motor High Speed Clockwise Rotation Air Motor High Speed Counter Clockwise Rotation Feed Tube Kit Feed Tube Kit Overhead Installation Feed Tube Kit Pit Mount Installation Clockwise Rotation
4. 503 Ali Pitter 3 4 NPT 11 _ 12 ee c e sj 11021 23 Plug 1 4 BER jj ______ C Apply 7969 10 Thread Sealer to all pipe threads prior to assembly AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 2 lt 2 sd Figure 15 78166 00 Air Assembly 78166 00 COMPRESSED AIR HOSE ASSEMBLY PARTS LIST Figure 15 E UI NND m al 1 78164 00 Hose 3 4 ID Push Lok Air __2 78165 00 Fitting Female SAE 45 Swivel X 3 4 ID Hose Lubricate the fitting and or hose ID with soapy water only DO NOT use heavy oil or grease AA 07 02 1 60 Ransburg Turbodisk Applicator Parts Identification SNOWOIN 9 JANA ANIGYNL zH 09 06 Hd dAv SL OL 2 092 001 ldN v 5 qanddns sz JAVA 440 1nHS AMO Nv31O 1455344402 TANVd 1OMINOO 38O1V10943 JAYA WON 438 A18W3SSV oslaogaint LIH N 4 OUMS 3M0SS323d oL INdNI HI 20 S gt gt lndNI 014 1 E e MI 3 T naos 09 0 iii ES YHS wi 51108 ONILNNOW 3SOIVOOMdIO3M TANVd 1OMINOO NI 39vn9 dMnsSdHd OL Figure 16 78781 00 Air Heater and Regulator Assembly AA 07 02 1 61
5. LNIVd 138 1 1 00 V1 LAASNI SOINOMIOJ 82 0 5 HUM 3Ovid3M NV GSN SI AI ILON Figure 10 70990 08 Turbodisk Assembly and Dump Valve AA 07 02 1 43 Turbodisk Applicator Parts Identification Ransburg 70990 08 TURBODISK ASSEMBLY TRIGGER AND DUMP VALVE PARTS LIST Figure 10 70976 01 Feed Tube Kit Downfeed 1 Part of 70988 XX These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit 8156 24F Screw 5 16 24 X 3 4 Hex Head 5 8156 32F Screw 5 16 24 X 1 Hex Head 5 t 1 8156 40F Screw 5 16 24 X 1 1 4 Heax Head 1 1 1 2 1 2 2 2 3 2 4 L Washer Spring 5 16 6 29 __ _15980 00 __ 1 2 10 1613 03 Tube Support 202386 1 2 11 Screw 5 16 24 X 1 1 2 Hex Head Not Used 2 13 27141 081 Hose Wrapping Not Shown SameagTR SSEM 082 o 2 14 15946 00 Grounding Hook Assembly Not Shown 2 15 10384 01 Tubing Latex 3 16 ID X 1 16 Wall Not Shown 50 These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly 9704 03 Tubing LD PE 1 4 OD X 17 ID 100 7113 13 Tubing 1 2 OD X 060 Wall Nylon 50 SSP 5020 Tubing 3 8 OD X 1 4 ID 100 Supplied with Kit 70977 04 only 55994 26 Tubing 1 2 OD X 3 8 ID Supplied with
6. with Kit 70977 04 Connector Straight 1 2 OD Tube X 1 4 NPT NS UM 4 ony These parts are supplied with Kit 70975 07 High Flow of 70975 09 Low Flow Trigger Valve W Regulator or Regulator Ready Indicates supplied W 70975 07 Only Indicates supplied W 70975 09 Only ap Connector Male 1 4 OD Tube X 1 4 NPT SS Elbow SST 1 4 NPT F X 1 8 NPT M pou ge Fitting SST 1 4 NPT Male Branch Tee ___ __________ 44 HIRPMOIOS Bracket 14112 45 CCV 12SS Valve Adapter 1 1 11111 46 __ 403 55 Trigger Valve Assembly Connector 1 4 OD Tube X 1 8 Male Brass 1 BS Tubing FEP 250 OD X 156 ID 48 5599424 Tubing FEP 2500DX 126ID S 5 Plug Hex Socket 1 4 NPT Screw 1 4 20 X 1 3 4 Lg Hex Head Bushing 1 2 Male X 1 4 Female SS Elbow Street 1 4 NPT SS Elbow Swivel Male 1 4 OD X 1 4 Brass 4 15 15 10007 01 Elbow 1 4 OD Tube X 1 4 NPT Male SS B Use as required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 105X Flow Rate mi min X Viscosity Poise X Fluid Length in Continued On Next Page Tube ID in AA 07 02 1 40 Turbodisk Applicator Parts Identification Ra nsburg 70990 07 TURBODISK ASSEMBLY TRIGGER VALVE ONLY PARTS LIST Continued Figure 9 These parts are supplied with Kit 70975 07 High Flow of 70975
7. Electrical Power Supply Type MicroPak Industrial or Voltage Master Charging Method Direct Input Voltage 0 100 kV Turbine Speed Control or Monitor PulseTrack 2 Optional Turbodisk Applicator Introduction Ra nsburg TYPICAL SPEED CHART 5 NOTES No Load Refer to Typical Speed Chart The following represents data collected under lab conditions Flow meters were installed on each of the two 3 8 inch ID heated air lines used to supply the Turbodisk 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 diskwas monitored through the means of a PulseTrack system The air heater was set at 120 degrees during all data collection Rotationalspeedsareunloadedand can be expected to drop 20 to 30 when under a fluid load condition Heated turbine air increases efficiency of motor up to 1096 This chart should be used as a guide ONLY Speeds will vary due to rotator wear tubing size or lengths etc NOTE Neverrun disk over it s maximum safe operating speed NOTE gt Air heater removes condensation from OD of motor at high speeds 7 AA 07 02 1 Turbodisk Applicator Introduction Ransburg TYPICAL SPEED CHART 10 HOLE ORIFICE PLATE NO LOAD 6 Conical Disk DiskSpeed Supply AirPressure Air Flow 1 Air Flow 2 Total AirFlow Total Air Flow RPM SLPM 2 5 5
8. Male 1 4 OD Tube X 1 4 SS Bracket Trigger Valve Assembly Connector 1 4 OD Tube X 1 8 Male Brass Tubing FEP 188 ID X 250 OD 4 Plug Hex Socket 1 4 NPT 4 13 LSFI0038 00 Elbow Street Reducing 1 8 NPTM X 1 4 NPTF SS 4 14 SSP 6439 Elbow Swivel Male 1 4 OD X 1 4 NPT Brass 4 15 76462 00 Service Tee NI 1 4 1 4 16 LSFI0006 01 Elbow 1 4 OD Tube X 1 4 NPT Female SS 1 4 1 4 4 4 5 4 6 4 7 4 8 9 o lt B Useas required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106 X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in Continued On Next Page AA 07 02 1 48 Turbodisk Applicator Parts Identification Ra nsburg 70990 09 TURBODISK ASSEMBLY IRIGGER VALVE ONLY W DR 1 REGULATOR PARTS LIST Cont Figure 11 These parts are supplied with Kit 70975 09 Trigger Valve Kit 418 4 19 55 8125_ 1 151 27 8 77 i o 5 i Tubing 1 4 OD X 1 8 ID 428 778702 Adapter 174 NPSF to NPTF Carbon Stee 1 O Oo Fitting Paint 250 Dia 4 30 8212 32 Screw Socket 10 32 B Use as required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106 X Flow Rate mi min X Viscosity Poise X Fluid L
9. Y PAINT 2 DUMP Y Y 1 REGULATOR LOW 42 REGULATOR LOW Y Y 1 REGULATOR HIGH 2 REGULATOR HIGH ReH 1 SUPPLY LINE Y PAINT 2 SUPPLY LINE P2S Y PAINT 2 TRIGGER PIT PANT 1 TRIGGER TURBINE AIR 2 TAL TURBINE AR 1 Y SOLVENT 2 SUPPLY SEIN SLIN SOLVENT 1 SUPPLY Y S1 IN T A1 S2 IN TA2 2 PIT 25 15 R2H RIH R2L RIL P2D P1D P2DL PIDL 2 FLUID 1 FLUID REGULATOR REGULATOR DR 1 DR 1 P2T P2D PID PIT P2DL P1DL 2 CCV TRIGGER VALVE 2 CCV DUMP VALVE n CCV DUMP VALVE n CCV TRIGGER VALVE S1JN CHECK VALVE S2 IN AF CHECK VALVE NOTE SOLVENT LINES ARE TO BE CONNECTED TO A REGULATED SOLVENT SUPPLY SEE OPTIONAL FLUSH TANK LFTS5000 OR SOLVENT VALVE LFTS5001 TURBINE AIR MOTOR ASSEMBLY Figure 6 Typical Trigger and Dump Valve Application with 2 DR 1 Fluid Regulators Schematic AA 07 02 1 Turbodisk Applicator Parts Iden
10. e The disk has stopped rotating The air supply to the trigger valves and regulator have been turned off e 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 Figure18 Removal 1 Remove disk mounting nut by holding the rota tor shaft above the disk with a 7 16 inch open end wrench and unscrewing the mounting nut with a 3 8 inch Allen wrench 2 Installthe ITW Ransburg 19850 00 disk puller into disk to remove it 3 Carefully remove lower fairing y WARNING gt Handle the disk with caution The sharp edge can cut even though it is not rotating 4 Next remove screws holding the fluid tube as sembly AA 07 02 1 Ransburg 5 With a 7 64 inch Allen wrench remove six 6 socket head cap screws which secures the turbine cartridge to the motor housing 6 Using a 1 16 inch Allen wrench turn each of the three 3 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 may result in misalignment and possible damage gt Use caution in removing cartridge to prevent it from falling out of the housing gt Any attempt to disassemble turbine dur ing the warranty period will void the war ranty Installation Alw
11. Turbodisk Applicator Parts Identification Ransburg 78781 00 AIR HEATER AND REGULATOR ASSEMBLY PARTS LIST Figure 16 78170 00 Regulator Assembly Turbodisk Drive Air 78166 00 Hose Assembly Compressed Air 11065 05 Air Heater Assembly gt 78176 01 Tubing 1 2 OD X 375 ID Green Nylon 200 ft WARNING gt air heater assembly must be located outside of any hazardous areas as defined by the NFPA 33 AA 07 02 1 62 Ransburg Turbodisk Applicator Parts Identification Figure 17 70158 00 Fairing Assembly AA 07 02 1 63 Turbodisk Applicator Parts Identification Ransburg 70158 00 FAIRING ASSEMBLY PARTS LIST Figure 17 70656 32 Screw Nylon 3 8 16 X 1 Lg Hex Head 8 20559 09 Washer Nylon Flat 3 8 ID 9 AU 81 02 1 Service Literature Not Shown 1 t Onup feed assemblies use 70913 feed tube bracket 1 Required amp 70914 01 clockwise feed tube or 70914 02 Ref counter clockwise feed tube on air motor AA 07 02 1 64 Ransburg Turbodisk Applicator Parts Identification COUNTER CLOCKWISE ROTATION 7 P N CLOCKWISE ROTATION LLL HI a 2 LT 1 IN 22 200 222
12. 15 000 18 2 260 20 000 27 8 9 Conical Disk Disk Speed Supply AirPressure Air Flow 1 Air Flow 2 Total Air Flow Total Air Flow PSI SLPM SLPM SLPM ws 12 Conical Disk DiskSpeed Supply AirPressure Air Flow 1 Air Flow 2 Total AirFlow Total Air Flow CAN SLPM SLPM SLPM M a 12 000 95 8 750 57 6 AA 07 02 1 8 Turbodisk Applicator Installation INSTALLATION EQUIPMENT This system should be installed by or under the supervision ofan Ransburgrepresentative Shouldthe needarisetoreplaceany componentassembly within 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 1 Air control of the applicator is from a standard Rans burg air logic panel which includestwofilters 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 mustbe provided totheinletfilter oftheairlogicstation viaa minimum 1 4 inch ID pipe and to the inlet filter of the heater panel via a minimum 3 4 inch ID pipe y WARNING gt The Air Heater Assembly must be located outside of any hazardous areas as d
13. Aluminum Anodized Uni Disk 6 Aluminum Not Anodized 10 Uni Disk Assy 12 Aluminum Not Anodized PARTS LIST BULLET DEFINITION TABLE E 1 Disk Mounting Nut See Table A is included with this assembly When mounting disk not included torque mounting nut to 50 60 Ibssin 5 65 6 75 Nm Recommended 3 8 hex bit socket with square drive torque wrench gt DR 1 Fluid Regulator 74151 XX can only be used with Fluid Control Valve Kits 70975 09 and 70975 10 as shown in Table C General Application Guideline Use DR 1 Regulator for paint flow rates from 25 to 1500 cc min High Flow Fluid Regulator 70171 04 can only be used with Fluid Control Valve Kits 70975 07 and 70975 08 as shown in Table General Application Guideline Use High Flow Regulator for paint flow rates above 750 cc min 31 AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 70988 BASIC SYSTEMS KIT 70988 01 DOWNFEED CLOCKWISE 7817502 AirMotor HighSpeed 1 Basic Mounting Parts Kit Feed Tube Kit Disk Puller Assembly 70988 02 DOWNFEED COUNTER CLOCKWISE Description Air Motor High Speed Basic Mounting Parts Kit Feed Tube Kit Disk Puller Assembly 70988 03 UPFEED CLOCKWISE Description 78175 02 Air Motor High Speed 70973 01 Basic Mounting Parts Kit 70976 02 Feed Tube Kit 19850 00 Disk Puller Assembly 70988 04 UPFEED COUNTER CLOCKWISE Description Air Motor
14. Feed Tube Kit Pit Mount Installation Counter Clockwise Rotation AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg PP TOOLS AND ACCESSORIES En f Low Flow 19850 00 DISK PULLER ASSEMBLY A11065 05 AIR HEATER CCV 7 VALVE TOOL 15946 00 GROUNDING HOOK ASSEMBLY AA 07 02 1 70 Turbodisk Applicator Warranty Policies 71 WARRANTY POLICIES LIMITED WARRANTY Ransburg will replace or repair without charge any part and or equipmentthat 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 writ ten 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 is one 1 year from date of purchase WRAPPING THE AP PLICATOR ASSO CIATED VALVES AND TUBING AND SUPPORTING HARDWARE IN PLASTIC SHRINK WRAP OR
15. 09 Low Flow Trigger Valve W Regulator or Regulator Ready Indicates supplied W 70975 07 Only Indicates supplied W 70975 09 Only Flow Regulator DR 1 Not Shown Fitting 1 4 OD Tube Special Not Shown Screw Regulator Mounting Not Shown 4 18 7787 02 Adapter 1 4 NPSF to 1 4 NPTF Carbon Steel Not Shown Tee Street 1 4 NPT Not Shown 1 4 19 55 8125 HexJamNu 1 420 20810 00 BrackeRegultor a 14 4 22 AU 81 07 Flow Regulator Service Manual 70171 04 O E MEN 4 22 LN 9223 00 9 DR 1 Fluid Regulator Service Manual 74151 XX 403 55 KK 4841 Repair Kit CCV 403 SS Not Shown LN 9100 00 CCV 403 SS Service Manual Not Shown 4 25 CCV 7 Valve Tool Not Shown 41 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 42 Ransburg Turbodisk Applicator Parts Identification 190 ASSV 4 XX 89 0 55 SATA A39 HL LO3NNU9 LIINI N3DDIML INIVd 71387 144 5 INIVd 7397 4434 01 uno g A3IA 9 INIVd 1381 qasn LON SI 1 2 MOlVOOMdlO3M OL 9NLNnOM 304 INV oL any OC ona 140 55 Andino YOLVINGSY OL LOSNNOO NOlvIno3H lNivd 138 1
16. Clockwise Rotation without Exhaust Adapter 0 70879 456 Air Motor Assembly Counter Clockwise Rotation with Exhaust Adapter See Parts List Bullet Definition Table PARTS LIST BULLET DEFINITION TABLE Figure 18 Tighten screws alternately to a final torque reading of 10 Ibs in 1 13 Nm Apply Petrolatum jell SSL 11 to o rings prior to assembly Apply 7969 10 thread sealer to male pipe threads prior to assembly The exhaust adapter is required only when the orientation of the fluid valving will not allow the exhaust muffle to be installed directly into the turbine housing If the installed system provides an interference then it may be possible to re orient the fluid valving so that the exhaust adapter is not required AA 07 02 1 66 Ransburg C W ROTATION C C W ROTATION TORQUE TO 10 LBS IN 39 54 Nm Turbodisk Applicator Parts Identification 22 N ay SS A EZ D S ss 5224 1 4 AL Ned Ny 2 Ly gt S AA 07 02 1 Figure 19 70879 XXX Turbodisk Turbine Cartridge Assembly TORQUE TO 10 LBS IN 1 13 Nm 2 67 Turbodisk Applicator Parts Identification Ransburg 70879 TURBODISK TURBINE CARTRIDGE ASSEMBLY PARTS LIST Figure 19 Screw 166 32 x 3 8 Long Hex Socket Flat Head 4 J Spacer Bearing CU UU UU I 2028890 TL 1 5 __ Bearing pal 860 2 O Ring 1 614
17. D 6 LABEL SOLVENT FLUSH LABEL ATOMIZER AIR 15 2 PLCS 2 AIR LINES REPLACE WITH 5 29 FOR FOTRONICS INSERT LA1003 NOTE IF PULSETRACK IS USED REMOVE PLUG AND DISK ASS Y OPT Figure 8 70990 06 Turbodisk Assembly 3 Way Valves 37 AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 70990 06 TURBODISK ASSEMBLY 3 WAY VALVES PARTS LIST Figure 8 1 Part of 70988 XX Kit Item Part Description 1 70976 01 Feed Tube Kit Downfeed These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit Screw 5 16 24 X 3 4 Hex Head Screw 5 16 24 X 1 Hex Head Screw 5 16 24 X 1 1 4 Heax Head L Washer Spring 5 16 2 Extension Arm Air Motor 2 10 Tube Support 20 3 8 2 11 8156 48F Screw 5 16 24 X 1 1 2 Hex Head Not Used 2 13 27141 081 Hose Wrapping Not Shown 2 1 2 2 2 3 2 4 9 Same TR SSEM 082 2 14 15946 00 Grounding Hook Assembly Not Shown 2 15 10384 01 Tubing Latex 3 16 ID X 1 16 Wall Not Shown 50 These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly 9704 03 Tubing LD PE 1 4 OD X 17 ID 7113 13 Tubing 1 2 OD X 060 Wall Nylon 50 SSP 5020 Tubing 3 8 OD X 1 4 ID 100 Supplied with Kit 70977 04 only 55994 26 Tubing 1 2 OD X 3 8 ID Supplied with Kit 70977 05 only 41 FTC 1002 Fitting Connector 3 8 T X 1 4 NPT Sup
18. Fluid Length in 55994 23 Tubing 156 IDX 253 OD Tube ID in 53 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 54 Turbodisk Applicator Parts Identification 55 SEE VIEW B LABEL PAINT SUPPLY OUTLET TOR BILL OF J 3 LINE da PART No 74151 XX CONNECT TO PAINT REGULATOR OUTPUT DR 1 SEE LABEL FROM PAINT REGULATOR OUTLET LABEL PAINT TRIGGER AIR e e 51 amp 5 2 8 8 FOR WOUNTING TO RECIROCATOR IF FAIRING IS NOT USED 5 z H IS USED REPLACE LABEL ATOMIZER AIR 15 2 2 AIR LINES Qnam PLUG ITE IF PUI Figure 13 70990 11 Turbodisk Assembly Dual DR 1 Regulators AND SPECIFIED RATIO MATERIAL 1 1 ILL Ol STEN LL PART No 45 VIEW B Ransburg fe TUBING 1 4 NPSF E kt OF MAI PART No 4728 1 PART No 4818 amp 70158 XX FAIRING ASS Y OPT AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 70990 11 TURBODISK ASSEMBLY DUAL DR 1 REGULATORS PARTS LIST Figure 13 70976 01 Feed Tube Kit Downfeed 1 Pet of 70988 XX These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit 815624 Screw 5 16 24 X 3 4 Hex Head C 2 0 815632
19. ID Solvent Resistant 755477 1 O Ring 3 489 ID Solvent Resistant 755473 1 8 Decaj202923 Tumbod amp k ____ 731882 t o key Woodruff 1 j gt 10 Nut Self Lock 5 818 7910 1 12 Spring Compression 7088800 1 13 Screw SetSpecal 708700 L 1 J Housing Bearing Machined 708750 O Ring 2 239 ID Solvent Resistant 7554 17 1 Plate Nozzle ELE See corresponding column Table TABLE Figure 19 70879 406 Motor Turbodisk Clockwise Rotation 20291 10 20292 31 70897 01 70879 456 Motor Turbodisk Counter Clockwise Rotation 20291 60 20292 32 70897 02 See Parts List Bullet Definition Table PARTS LIST BULLET DEFINITION TABLE Figure 18 Prime thread with P N 7991 00 primer Loctite 19267 bond with P N 7969 03 Loctite Blue 24077 8 These denote magnetic fiber optic assemblies Apply 7969 02 Red 27121 Loctite to threads This o ring to be assembled dry AA 07 02 1 68 Turbodisk Applicator Parts Identification Ra nsburg TURBODISK APPLICATOR RECOMMENDED SPARE PARTS Ccva0sss O SSWi04 HighVotageCabe O T J 55 809 01 ______ 7097794 WbesoD
20. be transmitted to the other race through the bearings Force and resist ance must always be on the same race in order to prevent damage Do not enlarge the nozzle passages during cleaning as it will effect performance Always observe the specified torque in tightening fasteners e Clean all parts thoroughly with an appropriate clean solvent Inspect them for wear or damage and replace as required e Check all flow passages for obstruction particularly the nozzle plate Clear as required Discard 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 Turbodisk Applicator Maintenance Ra nsburg TROUBLESHOOTING GUIDE Fluctuating Pattern 1 Not enough back 1 See regulator manual for diagnosis pressure on regulator Light Coverage on Some 1 Part hangers hooks are 1 a Clean hangers Parts not clean b Check ground continuity Must be less than 1 Megohm Poor Transfer Efficiency 1 Low voltage Check disk voltage with high voltage probe 2 Disk RPM to high Slow disk speed 3 Booth flow to high Reduce booth air flow 4 Diskedge to part Decrease conveyor loop diameter distance to great Low Current Readings 1 Dirty high voltage contacts 1 Clean and or replace High Current Readings 1 Target distance to close 1 Checktarget distance Ideal target distance is Pow
21. maintenance procedures should be estab lished and recorded at the initial start up All main tenance schedules are subject to variation based on use Periodically reviewthese maintenance schedules as equipment ages and needs change CLEANING PROCEDURES y WARNING gt Electrical shock hazards ist 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 human skin gloves or other materi als Be sure the disk atomizer has completely stopped spinning before attempting to touch it 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 equip ment Ransburg WARNING gt Because of the hazard of bearing pen etration solvents should be used sparingly They should NEVER be hosed directly onto the atomizer motor housing or any fiber optic juncture WARNING gt NEVER wrap the applicator in plastic to keep it clean A surface charge may build up on the plastic surface and discharge to the nearest grounded object Efficiency of the applicator will also be reduced and damage or failure of the applicator comp
22. rated speed K number as listed in the service manual Ex cessive speed may cause the disk to disinte grate causing serious damage and or injury All atomizers manufactured after April 6 1982 beara K number Thatnumberindicates the maximum safe rotation speed for that series in tens of thousands 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 ITW Ransburg repre sentative for its maximum safe operating speed y WARNING gt Inspect disk platter daily for wear or damage Replace if excessively worn or damaged Worn or damaged disk platters can cause an imbalanced condition and shorten bearing life Warranty will be voided if damaged disks are used Turbodisk Applicator Operation Ransburg TYPICAL MAXIMUM SAFE OPERATING SPEEDS None Disk Type Max RPM Conical Disk Assy Serrated 6 Aluminum Not Anodized 20485 62 40 000 Conical Disk Assy Serrated 6 Aluminum Anodized 20485 65 40 000 Conical Disk Assy Serrated 9 Aluminum Not Anodized 20485 92 25 000 Conical Disk Assy Serrated 9 Aluminum Anodized 20485 95 25 000 Conical Disk Assy Serrated 12 Aluminum Not Anodized 20485 122 15 000 Conical Disk Assy Serrated 12 Aluminum Anodized Uni Disk Assy 6 Aluminum Not Anodized Uni Disk Assy 8 Aluminum Not Anodized 20485 125 15 000 19830 06 27 000 19830 08 23 000 Uni Disk As
23. surface for paint residue gt Care must be taken when mounting the disk assembly to the motor shaft The mount ing nut should turn freely for several turns until it fully bottoms on the disk assembly Tighten to 50 70 Ibssin 5 65 7 91 Nm VIBRATION NOISE If the Turbodisk 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 WARNING gt Ifadisk has been mishandled or there appears to be damage on the face DO NOT USE Serious injury can result from rotating defective disk If there is a concern about the condition of a disk please return it to Ransburg for evaluation AA 07 02 1 Ransburg TURBINE REPAIR AND REBUILD Turbine motor must be returned to Ransburg for rebuilding Anyattemptto disassembleturbine during warranty period will void the warranty VALVES AND REGULATORS Nomaintenanceis normally required onthe valves or regulatorotherthanflushing with solvent daily Visual inspections should bemade onthevalves and regula tor on a weekly basis Should the valve or regulator notfunction properly refertothe individual manuals for troubleshooting and repair procedures PREVENTIVE MAINTENANCE Before any shutdown ormaintenance the fluid system should be thoroughly flushed All cleaning sho
24. 07 02 1 Litho in U S A 01 13 2013 Ransburg All rights reserved ISO 2001 Models and specifications subject to change without notice
25. 22 OSA 55555 ne 22 im 4 74 y DD 77777 MAS ZZ 7 42704 R222 DUTY TBA lt ia PROTEIN LER LLL 4 204 NN WEY SHOWN WITHOUT EXHAUST ADAPTER Figure 18 78175 XX Turbodisk Air Turbine Assembly AA 07 02 1 65 Turbodisk Applicator Parts Identification Ransburg 78175 TURBODISK AIR TURBINE ASSEMBLY PARTS LIST Figure 18 Screw 8 32 x 5 16 Long Slotted Round Head 7735 10C 8 ockWasher 8 Helical Spring 77 493 8 4 Plug Protective ___ 5005 1 6 Fitting Machined Exhaust MufflerAdapter 78130 Identification Cap 1 2 OD Tube Green 78169 00 2 8 Fitting 1 2 NPT x 1 2 OD Tube 78168 00 2 9 O Ring 4 239 ID x 070 CS Solvent Resistant 755474 2 gt Screw 88 32 x 3 8 Long Socket Head Set 7716 120 ___ 3 11 __ AirMotor Assembly Turbodisk 8 1 Screw 6 32 x 1 2 Long Socket Head Cap 10773 16C 6 gt 7612 43 See corresponding column in Table A TABLE A Figure 18 Der omm na 78175 01 Air Motor Assembly Clockwise Rotation without Exhaust 0 70879 406 gt Air Motor Assembly Counter
26. ANY OTHER NON APPROVED COVERING WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WAR RANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS Ransburg THERE ARE NO IMPLIED WARRAN TIES NOR WAR RANTIES OF EITHER MERCHANTABILITY OR FITNESS FORA 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 EXCLUSIONS Ransburg s opinion the warranty item in question or other items damaged by this part was improperly installed operated or maintained Ransburg will as sume noresponsibility for repair or replacement ofthe item or items The purchaser therefore will assume all responsibilityforany costofrepairorreplacement and service related costs if applicable AA 07 02 1 Ransburg AA 07 02 1 Service Manual Price 50 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 Technical Service Assistance Automotive Assembly and Tier I Telephone 800 626 3565 Fax 419 470 2040 Industrial Systems Telephone 800 233 3366 Fax 419 470 2071 Ransburg Guns Telephone 800 233 3366 Fax 419 470 2071 www ransburg com Technical Support Representative will direct you to the appropriate telephone number for order ing Spare Parts Form No AA
27. DEL IDENTIFICATION PARTS LIST oreet teneur Pete tre eret 29 31 70988 BASIC SYSTEMS KIT aactor ont tubae tinea 32 33 70990 05 TURBODISK ASSEMBLY NO VALVES PARTS c 35 36 70990 06 TURBODISK ASSEMBLY 3 WAY VALVES PARTS LIST e 37 38 70990 07 TURBODISK ASSEMBLY TRIGGER VALVE ONLY PARTS 39 41 70990 08 TURBODISK ASSEMBLY TRIGGER AND DUMP VALVE PARTS LIS T eoa iube nate 43 45 70990 09 TURBODISK ASSEMBLY TRIGGER VALVE ONLY W DR 1 REGULATOR PARTS 47 49 70990 10 TURBODISK ASSEMBLY TRIGGER AND DUMP VALVE W DR 1 REGULATOR PARTS 1 51 53 70990 11 TURBODISK ASSEMBLY DUAL DR 1 REGULATORS 55 57 78170 00 DRIVE AIR REGULATOR ASSEMBLY PARTS LIST 59 78166 00 COMPRESSED AIR HOSE ASSEMBLY PARTS LIST 60 78781 00 AIR HEATER AND REGULATOR ASSEMBLY PARTS LIST 61 62 70158 00 FAIRING ASSEMBLY 7 PARTS LIST anite eroe tant 63 64 78175 TURBODISK AIR TURBINE ASSEMBLY PARTS LIST 65 66 70879 XXX TURBODISK TURBINE CARTRIDGE ASSEMBLY PARTS E og pec 67 68 TURBODISK APPLICATOR RECOMMENDED SPARE
28. DESCRIPTION The Turbodisk Applicator because of it s high rota tional 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 opera tions Its speed is controlled by varying the drive air The applicator assembly is designed for use on vertical overhead mounted reciprocators Conical Disk Assembly TheTurbodisk Applicator uses conical disk assemblies that are made from high grade aluminum construc tion and are force balanced 10 grams in or better With the serrated edge these disks come in sizes of 6 9 and 12 inch diameters Turbodisk Fairing Refer to Figure 17 The Turbodisk Applicator fairing is required for safe operation The two piece fairing provides high volt age isolation from the metal rotator assembly and valve components as well as ease of cleaning and maintenance y WARNING gt Both sections of the fairing to be in place when the Turbodisk is in operation or when high voltage is supplied to the applicator AA 07 02 1 Ransburg Paint Valve Options Several valve options are available for both single and dual feed Options are No Valves 3 Way Valves Trigger and Dump Valves with DR 1 Regulator Trigger Valve Only Trigger and Dump Valves with Dual DR 1 Regulators e Trigger Valves with DR 1 Regulator Power Supply and Controls In th
29. FEP 188 ID X 250 OD 4 SSP 1421 Plug Hex Socket 1 4 4 13 LSFI0038 00 Elbow Street Reducing M8 NPTM X 1 4 NPTF SS 4 1 4 4 4 5 4 6 4 7 4 8 9 4 15 76462 00 Service Tee NI 1 4 4 16 15 10006 01 Elbow 1 4 OD Tube X 1 4 NPT Female SS 4 17 SSV 809 Check Valve 1 4 NPT 4 18 15 10007 01 Elbow Male SS B 5 required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106 X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in 515 lt 5 lt Continued On Next Page AA 07 02 1 52 Turbodisk Applicator Parts Identification Ra nsburg 70990 10 TURBODISK ASSEMBLY IRIGGER AND DUMP VALVE W DR 1 REGULATOR PARTS LIST Cont Figure 12 These parts are supplied with Kit 70975 10 Trigger Valve Kit LSMM0025 00 Bracket Regulator LSFI0018 01 Ferrule Kit Not Shown LN 9223 00 9 DR 1 Fluid Regulator Service Manual Not Shown LN 9100 00 CCV 403 SS Service Manual Not Shown KK 4841 Repair Kit CCV 403 SS Not Shown CCV 7 Valve Tool Not Shown 55994 24 Tubing 1 4 OD X 1 8 ID 7787 02 Adapter 1 4 NPSF to NPTF Carbon Steel 70589 05 Fitting Paint 250 Dia 8212 32F Screw Cap Hex Socket 10 32 B Use as required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106 X Flow Rate mi min X Viscosity Poise X
30. High Speed Basic Mounting Parts Kit Feed Tube Kit Disk Puller Assembly H Special Order Only AA 07 02 1 32 Turbodisk Applicator Parts Identification Ra nsburg 70988 BASIC SYSTEMS KIT Cont 70988 05 DOWNFEED CLOCKWISE DUAL FEED TUBE 70988 06 DOWNFEED COUNTER CLOCKWISE DUAL FEED TUBE i 70988 07 UPFEED CLOCKWISE DUAL FEED TUBE ps 70988 08 UPFEED COUNTER CLOCKWISE DUAL FEED TUBE gt Special Order Only 33 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 34 Ransburg Turbodisk Applicator Parts Identification 190 ASSSV ONIMIVS XX 8910Z 5 LON SI 2 MOIVOOMdlO3M OL ONLLNNON S3Nr 2 5014 2 91 YAZINOLY 73877 AlddNS INIVd T38V1 1M3SNI SOINOMIO 6Z OWS 3ovid3H 3AON33 ISN SI 8 Al 310N HSAH 1 4 105 13971 L E v U v Sv Mdldvav 434 00 418Z c r ASSV ASIQ 05 Turbodisk Assembly No Valves Figure 7 70990 AA 07 02 1 35 Turbodisk Applicator Parts Identification Ransburg 70990 05 TURBODISK ASSEMBLY NO VALVES PARTS LIST Figure 7 1 7097600 70976 01 Feed Tube Kit Downfeed Part of 70989 XX Kit These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit 8156 24F Screw 5 16 24 X 3 4 Hex He
31. ICS INSERT LAtoos NOTE IF PULSETRACK IS USED REMOVE PLUG ID REPLACE WITH SMC 29 8 2 E Bs g By 59 de lt DISK ASS Y AN SEE VIEW B Figure 9 70990 07 Turbodisk Assembly Trigger Valve Only 39 AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 70990 07 TURBODISK ASSEMBLY TRIGGER VALVE ONLY PARTS LIST Figure 9 70976 01 Feed Tube Kit Downfeed Part of 70988 XX Kit These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit 1 sex Screw 51624 3 4 HexHead Screw 5 16 24 X 1 Hex Head Ss 4 23 8156 40F Screw 5 16 24X1 1 4 HeaxHead 1 1 Washer Spring 5 16 29 15980 00 Extension Arm Air Motor 210 161303 Tube Support 2033 8 T 1 Screw 5 16 24 X 1 1 2 Hex Head Not Used 213 2714 081 Hose Wrapping Not Shown oOo o Same E ECCL 2 14 1594600 Grounding Hook Assembly Not Shown 1 o Tubing Latex 3 16 ID X 1 16 Wall Not Shown 50 1 These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly 9704 03 Tubing LD PE 1 4 OD X 17 ID 100 Tubing 1 2 OD X 060 Wall Nylon E iwaw 3 3 SSP 5020 Tubing 3 8 OD X 1 4 ID 100
32. Kit 70977 05 only 41 FTC 1002 Fitting Connector 3 8 T X 1 4 NPT PS Supplied with Kit 70977 04 4 only 15 0005 01 Connector Straight 1 2 OD Tube X 1 4 4 Supplied with Kit 70977 05 C These parts are supplied with 70975 08 High Flow or 70975 10 Low Flow Trigger Dump Valve W Regulator Ready Indicates supplied w 70975 08 only Indicates supplied w 70975 10 only 3 1 3 2 3 3 3 3 3 4 3 4 i 70590 01 Connector Male 1 4 OD Tube X 1 4 NPT SS LSFI0038 00 Elbow SST 1 4 NPT F X 1 8 NPT M 76462 00 Fitting SST 1 4 NPT Male Branch Tee Bracket 2 Valve Assembly Trigger and Dump Connector 1 4 OD Tube X 1 8 NPT Male Brass 55994 23 Tubing FEP 250 OD X 156 ID 55994 24 Tubing FEP 250 OD X 126 ID 4 1 4 2 4 3 4 5 4 7 SSP 1421 Plug Hex Socket 1 4 NPT 4 10 7958 56C Screw 1 4 20 X 1 3 4 Lg Hex Head 4 11 7734 06 L Washer 1 4 B Useasrequired to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in Continued On Next Page AA 07 02 1 44 Turbodisk Applicator Parts Identification Ra nsburg 70990 08 TURBODISK ASSEMBLY TRIGGER AND DUMP VALVE PARTS LIST Cont Figure 10 These parts are supplied with Kit 70975 08 High Flow or 70975 10 Low Flow Trigger and Dump Valve W Regulator or Regulator R
33. NTROL dumpline When actuated paintflow is directed tothe dump return line This provides a method of rapidly removing paint from the line for cleanin Trigger and Dump n Refer to Turbodisk Fluid and Air Pres actuated at the same time as the paint trigger valve sure Requirements since the trigger valve is intended to cause the fluid ThefluidvalvesintheTurbodiskareactuatedbyanair flow to the disk at the prescribed input pressure signal The air pressure must exceed 70 psi to assure properactuation ofthevalve Applying airtothe valve FLUID AND AIR PRESSURE RE actuator turns on the fluid flow for that valve QUIREMENTS The trigger valve controls the paint flow to the disk Refer to Turbodisk Fluid and Air Pres When actuated paint flows through the valve to sure Requirements the fluid tube The disk should spinning at a 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 Fluid and air pressure requirements are dependent on the fluid trigger valve configuration TURBODISK FLUID AND AIR PRESSURE REQUIREMENTS 3 Way ON OFF Trigger Dump Trigger Dump wl 18283 W High Flow W Low Flow 70171 04 DR 1 pce Regula Regulator Air Pilot Fluid 100 psi max 100 psi Regulator Air Inlet Trigger 120 psi max 70 100 psi 70 100 psi Dump Valve Fluid Inl
34. SERVICE MANUAL Ransburg x January 2013 TURBODISK APPLICATOR ASSEMBLY MODEL A11376 C 4 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 Applicator Contents Ransburg CONTENTS PAGE SAFETY 1 4 SAFETY PRECAUTIONS u n u aun Waaa 1 PIAZARDSZSAPEGUARDS sua Ea qahaq khuya 2 4 INTRODUCTION 5 8 FEATURES uu a 5 GENERAL DESCRIPTIQJNL saison conet eua Qa i etr a un 5 6 EE 6 TYPICAL SPEED CHART E 7 8 INSTALLATION 9 10 9 AIR CONTROL 9 ues nctm CG 9 INTERLOCKS 9 TYPICAL LAYOUT OF SYSTEM I A I h 10 OPERATION 11 15 AIR HEATER REQUIREMENTS 11 12 COATING MATERIALS 12 FLUID FLOW CONTROL u a a aasawa tds hene n t oo ai o 12 FLUID Q wa a aq Waaa 13 TURBODISK FLUID AND AIR PRE
35. SSURE REQUIREMENTS 13 TURBINE 5 14 TYPICAL MAXIMUM SAFE OPERATING SPEEDS a aa 15 ELECTROSTATIC VOLTAGE err rtt rt Nes tree ep 15 I exa do 15 MAINTENANCE 17 28 C 17 CLEANING PROCEDURES rrr unn a tor tir saco voro secos a rie 17 19 MIBRATION NOISE 555 HEINE IPC SU a b 19 TURBINE REPAIR AND 20 VALVES AND REGULATORS 20 PREVENTIVE MAINTENANCE sssusa sensies 20 21 DISASSEMBLY PROCEDURES RE rt E REESE OD ERE 21 22 TROUBLESHOOTING 23 TYPICAL NO VALVE APPLICATION SCHEMATIC 24 TYPICAL 3 WAY VALVE APPLICATION 5 25 Continued On Next Page Turbodisk Assembly Contents Ra nsburg Contents Cont PAGE MAINTENANCE Cont 17 28 TYPICAL TRIGGER AND DUMP VALVE APPLICATION W DR 1 REGULATOR SCHEMATIC 26 TYPICAL VALVE ONLY APPLICATION W DR 1 REGULATOR SCHEMATIC 27 TYPICAL TRIGGER AND DUMP VALVE APPLICATION W 2 DR 1 FLUID REGULATORS SCHEMATIC eese tenente tentent 28 PARTS IDENTIFICATION 29 70 A11376 TURBODISK ASSEMBLY MO
36. SYNSSAYd OL IAdNI Nd 425 09 0 LNdLNO SNOCYVZVH Figure 1 Typical Layout of System 10 AA 07 02 1 Turbodisk Applicator Operation Ra nsburg OPERATION Fluids and lubricants used in this system must contain NO silicones y WARNING gt DO NOT exceed the maximum flow rate of 1500 cc min during painting or purge cycles Excessive fluid flow may cause an imbalance condition and possibly premature bearing failure gt Do NOT 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 AIR HEATER REQU IREMENTS dry clean and free of oil or moisture The atmospheric dew point should be 10 F or Turbine drive air expands as it moves through the less The air heater used should be adjusted turbine wheel cavity and as it exits the turbine from only high enough to prevent condensation the exhaust port This expansion will cause cooling from forming on the motor housing or at the of the exhaust air and the surfaces it contacts This exhaust port cooling effect can cause surface temperatures to fall below the dew point of the booth which will result in condensation on the interior and exterior of the atomizer machine and its components It is even WARNING possible that the temperature of the supply air may be below the booth dew point even without additional gt Operators must
37. Screw STTE 24 XT Hex Head p 8156 40 crew 6 24 X 4 Heax Head 4 0 Washer Spring 6 4 00 High Voltage Connector Assembly 710 T6105 Support 20 37 8156 48 crew 6 24 X 1 Hex Head Not Used T4 046 00 rounding Hook Assembly Not Shown These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly TOT L l wor Tubing VT ODX 1770 ubing OD X060 Wall Nylon SSP 5020 Tubing 3 8 OD X 1 4 ID Supplied with Kit 70977 04 onl 55994 26 Tubing 1 2 OD X 3 8 ID Supplied with Kit 70977 05 onl 78006 00 Elbow 3 8 OD Tube X 1 4 Supplied with Kit 70977 04 onl 15 10005 01 Connector Straight 1 2 OD Tube X 1 4 ER Supplied with Kit 70977 05 onl 41 1002 Connector Straight 3 8 OD Tube X 1 4 These parts supplied with Kit 70975 11 Trigger Valve Kit Lo 70590 01 onnector Male 1 4 OD Tube X 1 4 NPT pou a AL 0038 00 bow 174 NPTF X 178 NP RPMOTO Bracket V Valve Adapter 76 DSK4000 Valve Assembly Trigger and Dump p 58 6054 onnector 1 4 OD Tube X 1 8 NPI Male Brass 49 994 25 ubing 188 ID X OD 5550478 0007 0 pow Male 0006 0 pow 1 4 OD X 1 4 NPI Female B Useas required to increase fluid pressure at regulator outlet to approx 5 20 psi Pres
38. ad 8156 32F Screw 5 16 24 X 1 Hex Head 8156 40F Screw 5 16 24 X 1 1 4 Heax Head 7734 07 L Washer Spring 5 16 2 1 2 2 2 3 2 4 2 9 Extension Arm Air Motor 2 10 Tube Support 20 3 8 2 11 Screw 5 16 24 X 1 1 2 Hex Head Not Used 2 13 Hose Wrapping Not Shown Same as TR SSEM 082 _ 2 14 15946 00 Grounding Hook Assembly Not Shown 2 15 10384 01 Tubing Latex 3 16 ID X 1 16 Wall Not Shown These parts are supplied with Kit 70977 04 3 8 OD Low Flow or 70977 05 1 2 OD High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly e z 9704 03 Tubing LD PE 1 4 OD X 17 ID 7113 13 Tubing 1 2 OD X 060 Wall Nylon SSP 5020 Tubing 3 8 OD X 1 4 ID Supplied with Kit 70977 04 Tubing 1 2 OD X 3 8 ID Supplied with Kit 70977 05 only 41 FTC 1002 Fitting Connector 3 8 T X 1 4 NPT Supplied with Kit 70977 04 3 1 32 3 3 3 3 3 4 4 3 15 10005 01 Connector Straight 1 2 OD Tube X 1 4 Supplied with Kit 70977 05 These parts are supplied with Kit 70975 05 No Valve Kit 15 10004 01 Street Tee 1 4 SS LSFI0006 01 Elbow 1 4 OD Tube X 1 4 NPT Female 55 SSV 809 Check Valve 1 4 NPT Male 15 10018 01 Ferrule Kit 1 2 Nylon Not Shown AA 07 02 1 36 Turbodisk Applicator Parts Identification Ra nsburg IF FAIRING IS NOT USED 2 1 FOR MOUNTING RECIPROCATOR 70158 FAIRING ASS Y OPT TUE los BEN
39. any safety inter locksare disabled during operation Frequent power supply shutdown indicates a problem in the system requiring correction Turbodisk Applicator Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas mustbe keptcleanto preventthe accumula tion 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 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 89C Spray booth ventilation must be kept at the rates re quired by NFPA 33 OSHA and local codes In addition ventilation mustbe maintained during cleaning opera tions 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 equip ment 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 installat
40. ays check the inside of the motor housing and clean if required with a minimum amount of an ap propriate cleaning solvent and a soft cloth 1 Using a 1 16 inch Allen wrench retract the three 3 jack screws 2 With o rings in place on the nozzle plate and housing insert the turbine cartridge into motor housing gt Lightly lubricate o rings with petroleum jelly before assembly Fit parts with o rings very carefully They must not be al lowed to distort unseat or break 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 Ibs in AA 07 02 1 Turbodisk Applicator Maintenance 4 To avoid losing the jack screws during normal operation torque 2 3 Ibs in 0 23 0 34 Nm Turbine Cartridge Service This cartridge is a precision instrument and should be handled with care The bearings are preloaded to 30 Ibs 13 6 Kg and dynamically balanced Turbine bearing unit must be returned to Ransburg for rebuilding gt Failure to observe the following cautions will result in diminished performance and premature motor failure NOTES e Never use any silicone compound in this system Never use any lubrication on the bearings Never use any solvent on the bearings e Never exert force on one race of a bearing assembly that may
41. be fully trained safe expansion cooling operation of electrostatic equipment Op erators must read all instructions and safety Condensation is especially probable in waterborne precautions prior to using this equipment applications when booth temperature and relative see NFPA 33 humidity levels are typically maintained very high This condensation will allow sufficient conductiv ity of the surfaces such that they act as an erratic ground source potential This can cause damage to As with any spray finishing system operation of ihe equipment the Turbodisk involves properly setting the oper ating parameters to obtain the best finish qual ity 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 Itis therefore a requirement that turbine exhaust air temperature be maintained about the booth dew point to prevent condensation from forming on atomizer surfaces Doing so will eliminate moisture as a potential defect in painted surfaces as well as extending equipment life Thus it is recommended thatair heaters be installed into the atomizerair supply lines i e turbine drive air The air heaters must be of sufficient capacity capable of raising the incoming air temperature at least 40 F 4 4 C at a flow rate of 60 SCFM per applicator Fluid Type Fluid Flow Ra
42. by soaking in an appropriate solventto loosen paint residue Do not soakfor more than a 24 hour period Useasoftcloth 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 retorqued to 24 Ibssin 2 71 Nm after cleaning Reinstall the disk and torque the mounting nut to 50 60 Ibsein 5 65 6 78 Nm WARNING gt Do 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 gloved hand against the edge This could cause physical harm and or damage to the disk y WARNING gt Replace disk platter if damaged War ranty will be voided if damaged dish platter is used y WARNING gt Inspect disk platter daily for wear or damage Replace if excessively worn or damaged Worn or damaged disk platters can cause an imbalanced condition and shorten bearing life Warranty will be voided if damaged disks are used Ransburg 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 an atomizer 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 oper ating at high speeds gt Before reinstalling the disk onto the shaft check and clean the tapered mating
43. e system the high voltage is supplied to the Turbodisk 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 micro processor controlled for diagnostics and communi cation 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 provenreliability They have variable voltage control many safety features remote analog voltage control capabilities AA 07 02 1 Turbodisk Applicator Introduction SPECIFICATIONS Mechanical Turbine Speed Variable to 40 000 rpm max 6 inch conical disk Turbine Type Ball Bearing Weight 57 165 approximately Length 36 inches Diameter 13 25 inches Turbine Air At max speed 40k rpm requires 103 1 psi and 61 1 SCFM unloaded See Typical Speed Chart in this section Air Temp F 120 F maximum at applicator Fluid Pressure Inlet See Fluid and Air Pressure Regulator in the Operation section Single Fluid Flow Range Waterborne To 1 200 cc min maximum Solvent Base To 1 500 cc min maximum High Solids To 1 000 cc min 80 maximum Air Inlet Trigger Dump 70 100 psi Air Pilot for Fluid Pressure See Fluid and Air Pressure Regu lator in the Operation section
44. eady Indicates supplied w 70975 08 only Indicates supplied w 70975 10 only 4 eooo VA NPTSS 20 Elbow Swivel Male 174 OD X 1 4 Brass Elbow 1 4 OD Tube X 1 4 Male 55 Elbow 1 4 X 1 4 Female SS 1 Dlow Regulator DR 1 x Shown Fitting 1 4 OD Tube Special Not shown 8212 32F Screw Regulator Mounting Not Shown 4 TH 4 18 T Carbon Steel Not Shown Tee Street 1 4 NPT Not Shown LSFI0018 01 E 4 22 AU 81 07 Flow Mantel Bd iil SETS 423 KK 4841 Repair Kit CCV 403 SS NotShown 1 ee ____ NN 1 ValveTool NotShovmi B 5 required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 10 X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in 45 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 46 Turbodisk Applicator Parts Identification Ra nsburg Figure 11 70990 09 Turbodisk Assembly Trigger Valve Only W DR 1 Regulator 47 AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg 70990 09 TURBODISK ASSEMBLY TRIGGER VALVE ONLY W DR 1 REGULATOR PARTS LIST Figure 11 dum 1 70976 01 Feed Tube Kit Downfeed 8156 24F T
45. ease in the bearings and cause failure Warranty will not cover this 20 Turbodisk Applicator Maintenance e Inspect the disk edge and face If damage exists DO NOT USE Return it to Ransburg for evaluation e Check the fluid feed tube to make sure it is not rubbing the disk Weekly Maintenance Follow the normal daily maintenance schedule then e Monitor rotational speed at the control and verify it is within 596 of target speed Monitor high voltage output indicated on the power supply display Verify with high voltage probe and meter e Remove fairing and clean all internal components valves regulators and tubing Check tubing for evidence of pin holes kinks and abrasions Ifthe 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 disk and manually triggering the paint valve Measure the amount of fluid in a graduated beaker over a specific time to determine flow rate e Clean and inspect the 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 21 Ransburg DISASSEMBLY PROCEDURES Prior to disassembly verify the following The atomizer disk valves and regulator have been flushed with solvent and purged dry with air
46. efined by the NFPA 33 Ransburg MOUNTING Refer to Figure 16 The Turbodisk assembly is mounted on the recipro cator using four 4 5 16 18 screws provided on the ram flange Loosening two 2 1 4 20 screws on the same ram flange will allow the assembly to rotate Position the Turbodisk assembly so that the strain relief boot is positioned toward the incoming fluid and air lines and retighten Remove lower fairing 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 larger in order to feed all the lines through Reinstall lower fairing Install conical disk and torque to 50 70 Ibssin 5 65 7 91 Nm INTERLOCKS Flow of coating material should be locked out unless all of the following conditions are met 1 Booth exhaust is turned on 2 The turbine is spinning 3 High voltage is on or in the bypass mode AA 07 02 1 Turbodisk Applicator Installation Ransburg SNOWOIN S JANA ANIGYNL ldN v u3sn wal JAVA 440 LNHS 4 GO8S WSS LN ANG 19 145544402 ISd 08 AlddNS Dunqsub 497 TANVd TOYLNOD 21901 5 ZH 09 0S Hd dAv 0 OVA0FZ 0ZL 2 TANVd 1OMINOO 3O1V10938 JAYA WOX T3NVd 1OMINOO 39vn9
47. ength in Tube ID in s N 49 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 50 Ransburg Turbodisk Applicator Parts Identification NER 58 SY oN 140 Assv 3SdN HOIO3NNOO PI pear 5 ON IsVd JO 7118 BS OLYA 03140395 3O1V10938 OL Iel 5 LON SI 4 MOIVOOMIOSM OL ONUNNOW 304 wAlddNS HSM OL BVI Andino solvin934 INIVd OL 103NNOO wolvino3s INNd WOU 3871 4J8nL Gadd OL LTUNO FATWA 8399141 INIVd T3HY1 ord SI MOVESTNd 31 ALON 434 00 82 82 5 2 62142 TagV1 3 55 VIO SIHL NI HS LON B Malin Figure 12 70990 10 Turbodisk Assembly Trigger and Dump Valve with DR 1 Regulator AA 07 02 1 51 Turbodisk Applicator Parts Identification Ransburg 70990 10 TURBODISK ASSEMBLY TRIGGER AND DUMP VALVE W DR 1 REGULATOR PARTS LIST Figure 12 Feed Tube Kit Downfeed These parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit Notes g m o
48. er Supply Overloads 12 inches minimum 2 Conductive paint 2 Solventbase paint conductivity should be 3 Fairing dirty between 05 and 20 megohms on Ransburg Paint Test Meter 4 High voltage cable break down 3 Clean with nonpolar solvent 5 Fluid tube pinholed to 4 Replace cable ground on conductive paint 5 Check tubing routing for areas where fluid tube systems comes near a ground Isolation mounting rod 6 Clean with nonpolar solvent or replace dirty or carbon tracked Low Voltage Power supply Use the following procedure to isolate problem Verify power supply output Refer to power Faulty high voltage switch supply manual for procedure or junction tank Remove the fairing and measure input voltage to the rotator assembly by removing the high High voltage cable voltage cable from the connector fitting and inserting it into the high voltage probe If voltage is low replace high voltage cable with a known good one and retest If voltage is still low check for bad connections in the high voltage Junction or Switch Tank Refer to procedures in the proper manual Reinstall the high voltage cable Check voltage at the rotator housing 23 AA 07 02 1 Turbodisk Applicator Maintenance Ransburg pp SOLVENT FLUSH PAINT SUPPLY CHECK VALVE AIR MOTOR ASSEMBLY ATOMIZER AIR DISK ASSEMBLY Figure 2 Typical No Valve Application Schematic AA 07 02 1 24 Turbodisk Applicator Maintena
49. et Pres 300 psi max 80 100 psi max 80 100 psi max sure Solvent Inlet 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 13 AA 07 02 1 Ransburg TURBINE SPEED Turbine speedis determined bythe driveair pressure at the rotary atomizer and fluid flow rate Turbine speed can be closed loop controlled using the fiber optic speed transmitter mounted atthe back of the turbine rotator assembly as a speed input to remote speed controls such as the PulseTrack 2 NOTE gt disk rotational speed determines the quality of atomization and can be varied for different flow rates and viscosities For optimum transfer efficiency and spray pat tern control the disk rotational speed should be set at the minimum required speed to achieve proper atomization Excessive speed reduces transfer efficiency WARNING gt exceed the maximum rated speed of 40 000 rpm for the 6 inch conical disk and 27 000 rpm for the 6 inch uni disk This maximum speed includes speed over shoot when fluid delivery is stopped Dam age to persons or equipment may result in over speed conditions AA 07 02 1 Turbodisk Applicator Operation Atomizers Refer to Typical Maximum Safe Operating Speeds WARNING gt Never operate any disk atomizer in excess of it s maximum
50. fety precautions must be read and understood prior to using this equipment Comply with appropriate local state and national codes governing ventilation fire protection operation mainte nance and housekeeping Reference OSHA NFPA 33 and your insurance company requirements 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 33 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety cir cuits disabled Before turning thehigh 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 trig gering valves etc Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying flushing or cleaning Read the label or data sheet for the material you intend to spray If in doubt as to whether or nota coating or cleaning material is com patible contact your material supplier Any other type of solvent may be used with aluminum equipment AA 07 02 1 Ransburg AREA Tells where hazards ma occur Toxic Substances Spray Area High Voltage Equipment Personnel Safety Mechanical Ha
51. 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 AA 07 02 1 Turbodisk Applicator Operation FLUID FLOW CONTROL Refer to Figures 14 and 15 Fluid flow control is dependent on the valve con figuration of the Turbodisk If the Turbodisk is con figured with no valves or a 3 way valve fluid flow is controlled externally at the paint source If the Turbodisk 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 how to control and deliver consistent fluid flows For more information 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 Proce dure The fluid can then be manually triggered to measure actual flow in a graduated beaker over a specified time period WARNING gt Danger of shock and or personal injury can occur Proper grounding procedures which are outlined in the ITW 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 Turbodisk Applicator Operation Ra nsburg FLUID VALVE CO
52. h DR 1 Fluid Regulator 1 10 Ratio 7097509 7415105 Trigger Valve with DR 1 Fluid Regulator 1 3 Ratio 7097509 7415106 Trigger Valve with DR 1 Fluid Regulator 1 1 Ratio 70975 09 74151 11 G H Trigger amp Dump Valve with DR 1 Fluid Regulator 1 2 Ratio 70975 10 74151 01 Trigger amp Dump Valve with DR 1 Fluid Regulator 1 4 Ratio 70975 10 74151 02 S J K Trigger amp Dump Valve with DR 1 Fluid Regulator 1 6 Ratio 70975 10 74151 03 7 E F J K M Trigger amp Dump Valve with DR 1 Fluid Regulator 1 8 Ratio 70975 10 74151 04 Trigger amp Dump Valve with DR 1 Fluid Regulator 1 10 Ratio 70975 10 74151 05 Trigger amp Dump Valve with DR 1 Fluid Regulator 1 3 Ratio 70975 10 74151 06 R Trigger amp Dump Valve with DR 1 Fluid Regulator 1 1 Ratio 70975 10 74151 11 Trigger amp Dump Valve with 2 DR 1 Fluid Regulator 1 1 Ratio 70975 11 74151 11 TABLE D HOSE FOR PAINT SYSTEM Nen ro AA 07 02 1 30 Turbodisk Applicator Parts Identification Ra nsburg TABLE E FIBER OPTIC PICKUP 0 g ml Fiber Optic Pickup SMC 29 TABLE F AIR HEATER 0 Nome Air Heater Manifold Package With High Flow Regulator 78781 00 Regulator Assembly No Heater 78170 00 TABLE DISK TYPE 00 None c r C P Disk Assy Serrated 6 Aluminum Not Anodized Disk Assy Serrated 6 Aluminum Anodized Disk Assy Serrated 12
53. hese parts are supplied with Kit 70973 01 Hardware amp Mounting Parts Kit 8156 24F Screw 5 16 24 X 3 4 Hex Head 2 8156 32F Screw 5 16 24 X 1 Hex Head 5 ty 1 1 1 1 1 1 8156 40F Screw 5 16 24 X 1 1 4 Heax Head 7734 07 L Washer Spring 5 16 17274 00 High Voltage Connector Assembly 2 1 2 2 2 3 24 6 25 29 1598000 Extension Arm Air Motor 1 2 10 16103 TubeSupport2o 3 h 1 25 2 5 2 11 8156 48F Screw 5 16 24 X 1 1 2 Hex Head Not Used 2 2 12 3923 02 Spiral Wrap 1 2 Not Shown 25 2 13 27141 081 Hose Wrapping Not Shown S 2 14 15946 00 Grounding Hook Assembly Not Shown 1 These parts supplied with Kit 70977 04 3 8 OD Low Flow 70977 05 1 2 High Flow Tube amp Fitting Kit Shipped loose as Kit no assembly ee 288 n 9704 03 Tubing LD PE 1 4 OD X 17 ID Tubing 1 2 OD X 060 Wall Nylon SSP 5020 Tubing 3 8 OD X 1 4 ID 100 Supplied with Kit 70977 04 Tubing 1 2 OD X 3 8 ID with Kit 70977 05 Elbow 3 8 OD Tube X 1 4 NPT Supplied with Kit 70977 04 Connector Straight 1 2 OD Tube X 1 4 with Kit 70977 05 Connector Straight 3 8 OD Tube X 1 4 iid These parts are supplied with Kit 70975 09 Trigger Valve Kit gt 2 3 1 3 2 3 3 3 3 3 4 3 4 3 5 70590 01
54. ions to spray solvent based materials The paint process and equipment should be set up and operated in accordance with NFPA 33 NEC and OSHA requirements Turbodisk Applicator Safety AREA Tells where hazards may occur General Use and Maintenance Electrical Equipment Explosion Hazard Incompatible Materi als HAZARD Tells what the hazard is Improperoperation ormaintenance may create a hazard Personnel must be properly trained in the use of this equipment 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 arc ing that may cause afire or explosion is lost if safety circuits are disabled during operation Frequent power supply shutdown indicates a problem in the system which requires correction An electrical arc can ignite coating materials and cause a fire or explo sion Halogenated hydrocarbon solvents for example methylene chloride and 1 1 1 Trichloroethane are not chemically compatible with the aluminum that might be used in many system components The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Personnel must be given training in accordance with the requirements of NFPA 33 Instructions and sa
55. nce Ra nsburg PAINT SUPPLY FLUID TRIGGER L PAINT RETURN LINE SOLVENT FLUSH ES CHECK VALVE AIR MOTOR ASSEMBLY ATOMIZER AIR DISK ASSEMBLY Figure 3 Typical 3 Way Valve Application Schematic 25 AA 07 02 1 Ransburg PAINT REGULATOR FLOW REGULATOR DUMP LINE DUM DUMP VALVE ATOMIZER AIR F CCV TRIGGER VALVE Turbodisk Applicator Maintenance PAINT SUPPLY PAINT RECIRCULATE PAINT TRIGGER SOVLVENT FLUSH NOTE THIS LINE IS TO BE CONNECTED TO A REGULATED SOLVENT SUPPLY SEE OPTIONAL FLUSH TANK LTFS5000 OR SOLVENT VALVE LTFS5001 CHECK VALVE AIR MOTOR ASSEMBLY DISK ASSEMBLY Figure 4 Typical Trigger and Dump Valve Application with DR 1 Regulator Schematic AA 07 02 1 26 Turbodisk Applicator Maintenance Ra nsburg PAINT SUPPLY PAINT RECIRCULATE PAINT REGULATOR FLOW REGULATOR PAINT TRIGGER SOLVENT FLUSH NOTE THIS LINE IS TO BE CONNECTED TO A REGULATED SOLVENT SUPPLY SEE OPTIONAL FLUSH TANK LTFS5000 OR SOLVENT VALVE LTFS5001 CHECK VALVE ATOMIZER AIR AIR MOTOR ASSEMBLY DISK ASSEMBLY Figure 5 Typical Trigger Valve Only Application with DR 1 Regulator Schematic 27 AA 07 02 1 Turbodisk Applicator Maintenance Ransbur PAINT 2 DUMP LINE PDL PAINT 1 DUMP LINE V PID PAINT 1 DUMP
56. nflammable nonpolar solvents for cleaning are Amyl acetate methyl amyl acetate high flash naphtha and mineral WARNING spirits gt Never submerge a disk into a solvent bath while still mounted on the shaft Sol Donotuse conductive solvents such as MEK to clean the external surfaces of the Turbodisk vent may intrude into bearing cavity and destroy the grease Remove disk to hand clean or run disk and flush through trigger and dump valves gt Never lower the Turbodisk assembly into a drum for flushing or color changing NOTE Disk Cleaning Solvent flushing of the system except Normally the internal cleaning instructions will suf during color change should be done with fice to clean the disk If flushing the disk does not the disk dismounted and with waste solvent remove all the residue the disk may be removed for collected in a grounded container hand cleaning Unscrew mounting nut and remove the disk by using the supplied disk puller NOTE gt turbine shaft must be held with a 7 16 open end wrench while using the disk puller y WARNING gt Do not hold disk edge during removal This could result in injury AA 07 02 1 18 Turbodisk Applicator Maintenance 19 Inspection of the disk is required to determine if wear to the serrated edge or damage has occurred Wear cause a reduction in transfer efficiency and excessive paint wrap on the atomizer fairing Clean the disk
57. onents may occur WRAPPING THE APPLICATOR IN PLAS TIC WILL VOID WARRANTY gt immerse the Turbodisk assembly in solvent or other liquids Turbine compo nents will be damaged gt soak the disk in solvent longer than 24 hours WARNING gt Inspect disk platter daily for wear or damage Replace if excessively worn or damaged Worn or damaged disk platters can cause an imbalanced condition and shorten bearing life Warranty will be voided if damaged disks are used AA 07 02 1 nsburg Turbodisk Applicator Maintenance Internal Fluid Path Cleaning External Atomizer Surface Cleaning With the high voltageturned offand the diskspinning flush cleaning solvent through the incom ing paint line or through the solventinletline If itis desired to clean just the face of the disk off flush solvent through A the solvent inlet If a color change is required flush gt To reduce the risk of fire or explosion the entire system The spinning disk will atomize the OSHA and NFPA 33 require that solvents solvent and clean outthe disk passages If equipped used for exterior cleaning including disk triggerthedumpvalvetocatchthe wasted paintfrom cleaning and soaking be nonflammable the incoming line then flush the disk with solvent flash points higher than 100 F 37 8 C after closing the dump valve Since electrostatic equipment is involved these solvents should also be nonpolar Ex amples of no
58. plied with Kit 70977 04 4 only 4 Supplied with Kit 70977 05 only 3 1 3 2 3 3 3 3 3 4 3 4 15 10005 01 Connector Straight 1 2 OD Tube X 1 4 y y These parts are supplied with Kit 70975 05 3 Way Valve Kit LSFI0004 01 Street Tee 1 4 NPT SS 15 10006 01 Elbow 1 4 OD Tube X 1 4 NPT Female SS SSV 809 Check Valve 1 4 NPT SS 55994 23 Tubing FEP 156 ID X 25 OD 18283 02 Valve Assembly 3 Way Elbow Street 1 4 NPT SS Reducer 1 8 NPT Male X 1 4 NPT Female SS 4 Elbow 1 4 OD Tube X 1 8 NPT Brass 4 10 Connector Male 1 4 OD Tube X 1 4 NPT SS 4 11 Screw 5 16 32 X 1 1 4 Lg Hex Head 4 12 7734 07 L Washer 5 16 4 13 Repair Kit 3 Way Valve Not Shown 4 14 LSFI0018 01 Ferrule Kit Not Shown 4 1 4 2 4 3 4 4 4 6 4 7 4 8 9 AA 07 02 1 38 Turbodisk Applicator Parts Identification Ra nsburg 4 LABEL PAINT TRIGGER AIR SEE LABEL FROM PAINT REGULATOR OUTLET CONNECT TO PAINT REGULATOR OUTPUT LABEL PAINT TRIGGER INLET CONNECT TO CCV VALVE ASS Y VIEW B 3 LABEL PAINT SUPPLY OUTLET 0 1 LABEL FLUSH TANK LABEL PAINT TRIGGER VALVE DUTLET FEED TUBE VIEW A FOR MOUNTING RECIPROCATOR IF FAIRING IS NOT USED 70158 XX FAIRING ASS Y OPT G LABEL PAINT REGULATOR PILOT AIR G FLUSH TANK FOR FOTRON
59. pray area must be grounded Unless specifically approved for use in hazardous loca tions 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 Ifthediskhas been rotating allow atleast three minutes for it to come to a complete stop before touching it Turbodisk Applicator Introduction INTRODUCTION FEATURES Features which make the Turbodisk Applicator advantageous for use in electrostatic applications include Proven turbine motor reliability 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 e A majority of all assembly components which come in contact with the fluid material are made of stainless steel which is impervious to most fluids e Negligible maintenance down time 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 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
60. study and continued use of this manual will provideabetterunderstanding of the equipment and process resulting in more efficient operation longer trouble free serviceand faster easier troubleshooting If you do not have the manuals and safety literature foryour Ransburg system contact your local Ransburg representative or Ransburg Ransburg WARNING gt The user MUST read and be familiar with the Safety Section in this manual and the Rans burg safety literature therein identified gt This manual MUST be read and thor oughly understood by ALL personnel who operate clean or maintain this equipment Special care should be taken to ensure that the WARNINGS and safety requirements for operating and servicing the equipment are followed The user should be aware of and ad here to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STAN DARD prior to installing operating and or servicing this equipment WARNING gt hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 AA 07 02 1 Ransburg AREA Tells where hazards may occur Spray Area AA 07 02 1 HAZARD Tells what the hazard is Fire Hazard Improper or inadequate operation and maintenance procedures will cause a fire hazard Protection against inadvertent arc ing that is capable of causing fire or explosion is lost if
61. sue Change Across Tubing PSI 601 X 105 X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in Continued On Next Page AA 07 02 1 56 Turbodisk Applicator Parts Identification Ra nsburg 70990 11 TURBODISK ASSEMBLY DUAL DR 1 REGULATORS PARTS LIST Cont Figure 13 These parts are supplied with Kit 70975 11 Trigger Valve Kit LSF10018 01 Ferrule Kit Not Shown _ gt ______ 422 1N 9223 009 DR 1 Fluid Regulator Service Manual Not Shown 1 Tubing 1 4 OD X 1 8 ID 70589 05 Fitting Paint 250 Dia 8212 32F Screw Cap Hex Socket 10 32 B 5 required to increase fluid pressure at regulator outlet to approx 5 20 psi Pressue Change Across Tubing PSI 601 X 106 X Flow Rate mi min X Viscosity Poise X Fluid Length in Tube ID in 57 AA 07 02 1 Ransburg AA 07 02 1 Turbodisk Applicator Parts Identification NOTES 58 Turbodisk Applicator Parts Identification Ra nsburg 59 CLEAN DRY AIR BY CUSTOMER WHEN MOUNTING REGULATOR ASSEMBLY THE ORIENTATION OF THE FILTER IS TO BE VERTICAL AS SHOWN Figure 14 78170 00 Drive Air Regulator Assembly 78170 00 DRIVE AIR REGULATOR ASSEMBLY PARTS LIST Figure 14 Elbow 1 4 OD Tube X 1 4 NPT Male Swivel Fitting 3 4 X SAE 45 Male Connector eed EET _8 4 001 Nipple 1 NPT X 3 4 NPT Hex Reducing 2 9
62. sy 10 Aluminum Not Anodized 19830 10 15 000 Uni Disk Assy 12 Aluminum Not Anodized ELECTROSTATIC VOLTAGE In the system the high voltage is supplied to the Tur bodisk by eitherthe MicroPak Industrial power supply system or Voltage Master series power supplies The MicroPak industrial power supply uses proven high voltage generator technology that is micro processor controlled for diagnostics and communi cation The controller is packaged in standard rack mounted Eurocard format for easy access and system integration The Voltage Master power supplies are general pur pose heavy duty power supplies with years of proven reliability They have variable voltage control many safety features and remote analog voltage control capabilities 19830 12 15 000 TARGET DISTANCE The distance between the Turbodisk and the target will affect the finish quality penetration and ef ficiency 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 305mm minimum for optimum performance AA 07 02 1 Ransburg AA 07 02 1 NOTES Turbodisk Applicator Operation Turbodisk Applicator 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 indica tions of component failure Normal
63. te Turbine Speed Electrostatic Voltage Target Distance The actual air heater process setting depends on the applicator fluid flow rate load booth conditions tur bine airflow settings and incoming air temperature 11 AA 07 02 1 Ransburg The heater should be setas low as possible sufficient to maintain the applicator surface temperatures above the dew point in the booth Example Only with the incoming air temperature at 72 F 22 2 C adiskrotating unloaded at 30 krpm has a turbine outlet temperature drop of approximately 28 F 2 2 C 40 krpm unloaded DT 14 F 10 C Referring to the ASHRAE Psychrometric chart the saturation temperature range dew point of a spray booth maintained at 70 75 F 65 70 RH is 62 68 F 21 1 23 9 C 76 70 RH is 16 7 20 C Thus it is almost certain that the surface temperatures of the applicator will fall below the dew point of the booth and an air heater will be needed in this case To prevent condensation an air heater assembly should be assembled after air filters Reference the current Air Heater Assembly service manual for further information NOTE gt Failure to use an air heater may cause damage to equipment or ruin the finished component being processed COATING MATERIALS The Turbodisk can be used with a broad range of coating material conductivities However with wa terborne paints it may be necessary to isolate the paint supply
64. tification Ra nsburg PARTS IDENTIFICATION A11376 TURBODISK ASSEMBLY MODEL IDENTIFICATION Turbodisk Assemblies are available with the various options as follows ModelNo 1136 X XX X X X XX Part G Disk Type Part F Air Heater Part E Fiber Optic Pickup Part D Paint Hose Part C Fluid Control Valve Kit Part B Fairing Part A Basic Systems Kit With High Speed Air Motor Basic Part Number TABLE A BASIC SYSTEMS KIT W HIGH SPEED AIR MOTOR Mounting Dash Description Kit Part Nut 1983601 19836 02 19836 03 1983607 19836 05 79836 06 Upfeed Clockwise Not Tilt Dual Feed Tube 70988 07 19836 07 08 Upfeed Counter Clockwise Tilt Dual Feed Tube 70988 08 19836 08 29 AA 07 02 1 Turbodisk Applicator Parts Identification Ransburg pp TABLE B FAIRING _ None ___ __ TABLE C FLUID CONTROL VALVE KIT DR 1 or EIE High Flow Dash st Description Kit Part No Valves or Fluid Regulator 70975 05 70975 05 6 3 Way Valve No Fluid Regulator 70975 06 70975 06 Trigger Valve with High Flow Fluid Regulator 70975 07 70171 04 8 Trigger amp Dump Valve with High Flow Fluid Regulator 70975 08 70171 04 A A Trigger Valve with Fluid Regulator 122 Ratio 7097509 7415141 Trigger Valve with DR 1 Fluid Regulator 1 4Ratio 7097509 7415102 74151 03 D rigger Valve with DR Fluid Regulator 1 8 Rato 7097509 7415104 E trigger Valve wit
65. uld be done with a minimum of the appropriate clean solvent and clean soft lint free rags or soft brushes where indicated WARNING gt Do not stop disk rotation by using a rag gloved hand gt sure high voltage is off before ap proaching applicator gt Follow proper grounding procedures AA 07 02 1 Turbodisk Applicator Maintenance gt Because of the hazard of bearing pen etration solvents should be used sparingly They should never be hosed directly onto the atomizer motor housing or fiber optic juncture y WARNING gt Personnel working on applicators MUST always be sure that the high voltage is off the fluid system is flushed and off the rota tor has stopped and that the grounding hook has been properly secured to the mo tor housing Daily Maintenance Clean the atomizer disk motor housing fairing and as needed the peripheral equipment with nonpolar high flash point solvents To prevent solvent penetration beyond the slinger a minimal air pressure of 5 to 10 psi should be applied to the motor in order to 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 y WARNING gt Positive air pressure must be maintained to prevent solvent or paint intrusion into the bearings Solvent and or paint will degrade the gr
66. zards AA 07 02 1 HAZARD Tells what the hazard is Certain material may be harmful if inhaled or if there is contact with the skin There is a high voltage device that can induce an electrical charge on 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 At these speeds the edge of the applica tor can easily cut into skin Loose articles can also be caught by the rotating disk Turbodisk Applicator Safety SAFEGUARDS Tells how to avoid the hazard 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 mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compat ible with the material being sprayed and its concentra tion Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved Parts being sprayed must be supported on conveyors or hangers and be grounded The resistance between the part and ground must not exceed 1 megohm Allelectrically conductive objectsinthe 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 s

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TURBODISK ™ APPLICATOR ASSEMBLY