Carlisle Ransburg CCV-5100 User manual

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SPECIFICATIONS
Maximum air inlet pressure: 7 bar [105 psi]
Air requirements (operating pressure): 4.8-6.9 bar [70-100 psi]
Air inlet ports (1x per valve): 1/8" NPT (f)
Maximum fluid pressure: 20.7 bar [300 psi]
Fluid inlet ports (2x per valve): 1/4" NPT (f)
Fluid outlet connection: 1/4" NPT (f)
Fluid flow capacity: 3800 cc/min @ 47 psi pressure drop
(paint viscosity = 700 centipoise)
Varies according to material pressure and viscosity.
Valve actuation speed (ON/OFF cycles): 55 cycles/min
Maximum number of colors: 30
Wetted parts: 300 series Stainless Steel, PTFE
EN
SERVICE MANUAL
CCV-5100 COLOR VALVE STACKS
LOW PRESSURE

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DJ Hasselschwert
Toledo, OH 43612
4-3191R-2
10-Mar-16
Signed for and on behalf of
Carlisle Fluid Technologies:
Machinery Directive 2006/42/EC
ATEX Directive 2014/34/EU
by complying with the following statutory documents and harmonized standards:
EN ISO 12100:2010 Safety of Machinery - General Principles for Design
EN 1127-1:2011 Explosive atmospheres - Explosion prevention - Basic concepts
EN 13463-1:2009 Non electrical equipment for use in potentially explosive atmospheres - Basic methods and requirements
EN 13463-5:2011 Non electrical equipment for use in potentially explosive atmospheres - Protection by constructional safety
The object of the declaration described above is in conformity with the relevant Union harmonisation legislation: Directive 94/9/EC
(until April 19th, 2016) and Directive 2014/34/EU (from April 20th, 2016)
Providing all conditions of safe use / installation stated within the product manuals have been complied with and also installed
in accordance with any applicable local codes of practice.
(Vice President: Global
Product Development)
The object of the declaration described above is in conformity with the relevant Union harmonisation
legislation:
This Declaration of Conformity
/incorporation is issued under the sole
responsiblility of the manufacturer:
Carlisle Fluid Technologies,
320 Phillips Ave.,
Toledo, OH 43612
EU Declaration of Conformity
Protection Level:
II 2 G X
Notified body details and role:
Element Materials Technology. WN8 9PN UK
Lodging of Technical file
Product Description/Object of Declaration:
Solvent and Water based Materials
Zone 1
Suitable for use in hazardous area:
This Product is designed for use with:
Color Stacks - CCV-51xx

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In this part sheet, the words WARNING, CAUTION and NOTE are used to
emphasize important safety information as follows:
DE-ENERGIZE, DEPRESSURIZE, DISCONNECT AND LOCK
OUT ALL POWER SOURCES DURING MAINTENANCE
Failure to De-energize, disconnect and lock out all power supplies
before performing equipment maintenance could cause serious
injury or death.
OPERATOR TRAINING
All personnel must be trained before operating finishing
equipment.
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture,
malfunction, or start unexpectedly and result in serious injury.
PROJECTILE HAZARD
You may be injured by venting liquids or gases that are released
under pressure, or flying debris.
PINCH POINT HAZARD
Moving parts can crush and cut. Pinch points are basically any
areas where there are moving parts.
INSPECT THE EQUIPMENT DAILY
Inspect the equipment for worn or broken parts on a daily basis.
Do not operate the equipment if you are uncertain about its
condition.
In this part sheet, the words WARNING, CAUTION and NOTE are used to
emphasize important safety information as follows:
Hazards or unsafe practices which
could result in minor personal injury,
product or property damage.
!
CAUTION
Hazards or unsafe practices which
could result in severe personal
injury, death or substantial property
damage.
!
WARNING
Important installation, operation or
maintenance information.
NOTE
Read the following warnings before using this equipment.
READ THE MANUAL
Before operating finishing equipment, read and understand all
safety, operation and maintenance information provided in the
operation manual.
WEAR SAFETY GLASSES
Failure to wear safety glasses with side shields could result in
serious eye injury or blindness.
NEVER MODIFY THE EQUIPMENT
Do not modify the equipment unless the manufacturer provides
written approval.
IT IS THE RESPONSIBILITY OF THE EMPLOYER TO PROVIDE THIS INFORMATION TO THE OPERATOR OF THE EQUIPMENT.
FOR FURTHER SAFETY INFORMATION REGARDING THIS EQUIPMENT, SEE THE GENERAL EQUIPMENT SAFETY BOOKLET (77-5300).
KNOW WHERE AND HOW TO SHUT OFF THE EQUIPMENT
IN CASE OF AN EMERGENCY
HIGH PRESSURE CONSIDERATION
High pressure can cause serious injury. Relieve all pressure before
servicing. Spray from the spray gun, hose leaks, or ruptured
components can inject fluid into your body and cause extremely
serious injury.
NOISE HAZARD
You may be injured by loud noise. Hearing protection may be
required when using this equipment.
STATIC CHARGE
Fluid may develop a static charge that must be dissipated through
proper grounding of the equipment, objects to be sprayed and all
other electrically conductive objects in the dispensing area. Improper
grounding or sparks can cause a hazardous condition and result in
fire, explosion or electric shock and other serious injury.
KEEP EQUIPMENT GUARDS IN PLACE
Do not operate the equipment if the safety devices have been
removed.
!
WARNING
PACEMAKER WARNING
You are in the presence of magnetic fields which may interfere
with the operation of certain pacemakers.
PRESSURE RELIEF PROCEDURE
Always follow the pressure relief procedure in the equipment
instruction manual.
AUTOMATIC EQUIPMENT
Automatic equipment may start suddenly without warning.

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COLOR VALVE STACK – SELECTION CHART
Color Stack Assembly
Number of Color Valves
Identication No. CCV-51 XX - X X X
Air Push Valves
0 = No Air Push Assembly
1 = One Air Push Assembly
2 = Two Air Push Assemblies
Note: Includes check valve, regulator, and gauge.
Fluid Inlet Fittings
0 = No Fittings Required
1 = Elbows Only
2 = Tee Only
Check Valves
0 = No Check Valves
1 = Check Valves On All Color
Valves
The following is for “Pre-Engineered Color Valve Stack
Assemblies”. Please reference “Color Valve Stack Selection
Chart” for the stack assembly number.
Part Number CCV-51XX-XXX identifies the configuration of the
stack assembly.
(CCV-51)XX-XXX
COLOR STACK ASSEMBLY
Includes the top block and solvent valve. The solvent valve is
always supplied with a check valve and a 3/8-inch ODT
stainless steel female elbow for fluid inlet.
CCV-51(XX)-XXX
NUMBER OF COLOR VALVES
(Selection 00-30). These two numbers indicate the number of
valves required for paint inlet to the stack assembly.
CCV-51XX-(X)XX
AIR PUSH VALVES
(Selection 0, 1, 2). This number indicates the number of “air
push” valves required. Each valve is supplied with a check
valve, gauge, regulator, and 3/8-inch ODT brass push style
fitting for air inlet. The air push is used to push out residual
paint in the fluid supply line. This air is also pulsed on and off
with the solvent to create a scrubbing action. In the event
that two different pressures are required, two air push valves
can be supplied.
COLOR VALVE STACK ASSEMBLIES OPTIONS
CCV-51XX-X(X)X
CHECK VALVES
(Selection 0, 1). This number indicates whether check valves
are supplied on the paint inlet valves. Check valves are used
to prevent materials from contaminating each other in the
event that two valves would be opened at the same time.
Check valves will always be supplied on solvent and air
valves, regardless of selection made here.
NOTE
CCV-51XX-XX(X)
FLUID INLET FITTINGS
(Selection 0, 1, 2). This number indicates whether no fitting,
elbows, or tees are supplied for the fluid inlet to the color
valves. Elbows are typically utilized for fluid inlet. Tees are
used for circulating the paint at the color valve. The elbows
and tees are stainless steel and accept a 1/4-inch OD fluid
line.
All valves are supplied with a brass push style, swivel elbow
for the air pilot. This fitting accepts a 1/4-inch OD tube.

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COLOR VALVE STACK – INSTALLATION
Figure 1: Typical Color Change Stack
* Included in KK-4901 Manifold Assembly Kit.
LSFI0033 Adapter
The CCV-403-SS valve mounted at this position is used
for solvent ushing of the manifold assembly. Connect the
solvent feed line to this valve. (Check valve is always used
on input port of CCV).
GA-338 Gauge
HAR-503-1 Air Regulator
23165-430* O-Ring (not shown)
The CCV-403-SS valve
mounted at this position
is used for air push of the
manifold assembly. Connect
the main air line to the regu-
lator. (Check valve is always
used on input port of CCV.)
CCV-16-SS Manifold Block
SSF-6504* Threaded rod - 4 required.
Cut to proper length at assembly.
SS-655-ZN* Nut -
4 required. (tighten to
110-130 in lbs)
CCV-37 Manifold
Mounting Bracket -
2 required
CCV-18-SS
Open Manifold End Cap
Fluid Inlets - Fittings must
be specied on Standard
Stacks. Tee ttings (SSP-
6810, 3/8” Male Branch Tee)
or 3/8” Elbows (SSP-6435)
may be used. Plug opposite
port with SSP-1421 Pipe Plug
if necessary.
Use nylon tubing for all uid
lines, 1/4” O.D. or larger.
Do not use polyethylene for
uid.
SS-10022* Cap Screw (4) required
CCV-17-SS End Valve Manifold Block
Check valves are always used on input ports of Air Push and
Solvent CCV’s They are optional for Color CCV’s.
NOTE

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Figure 2: Two Valve Manifold Assembly
Figure 3: Manifold Divider Block
Figure 4: Available Manifold Blocks
Figure 4 shows the four manifold blocks that can be used in a
manifold system. In additon, CCV-36-SS separator plate (Figure 2)
can also be used. In Figure 4, shown by the block inlets/outlets,
are numbers indicating hardware to be installed at these locations.
The dotted lines indicate the path of the mounting studs which
hold the blocks in place. The o-ring slots are shown (o-rings are
not included on CCV-18-SS). O-rings are included in KK-4901
Manifold Assembly Kit.
KK-4901 MANIFOLD ASSEMBLY KIT
The kit includes threaded rod, lockwashers, nuts, two (2)
mounting brackets, and twelve (12) o-rings which will allow
assembly. A spanner tool, part CCV-7, is also included in this kit.
This tool inserts into any one of the holes in the spanner nut and
is used to tighten or loosen the nut. This is convenient in close
clearances where a wrench may not t.
1 = CCV-403-SS = Valve Assembly
2 = KK-4370 = Plug Kit
3 = LSFI0033 = Adapter
LSFI0033 Adapter
CCV-17-SS End Valve
Manifold Block
CCV-38-SS Manifold
Divider Block
CCV-16-SS
Manifold Block
CCV-18-SS Open
Manifold End Cap
1 or 2
1 or 2
1 or 2 1 or 2
1 or 2 1 or 2
3
3
CCV-36-SS
Separator Plate CCV-18-SS
Open Manifold End Cap
41-FTC-1002 Adapter CCV-38-SS Manifold
Divider Block
COLOR VALVE STACK – INSTALLATION
Tighten CCV-403-SS valve assembly and KK-4370 plug kit
(when used) to manifold using 132-156 lbs•in torque. DO
NOT OVER-TIGHTEN. USE A GOOD QUALITY PIPE SEALANT
ON ALL THREADS OF AIR AND FLUID CONNECTIONS.
Do NOT use sealant or tape on CCV-403-SS valve when
assembling to manifold.
NOTE
INSTALLATION AND OPERATION OVERVIEW
The coating material is supplied from the users pressurized
system that may be a pressure tank, paint circulating system
or other suitable pressure paint supply system. 3/8-inch OD
fluid tubing is connected between the users paint supply and
the CCV.
An air signal supplied to the CCV activates the paint being
delivered to the applicator.
CCV Valve must be supported while tightening the tube
fittings to prevent damage to the valve seats, or remove the
valve before tightening the fluid inlet fittings.
Circulation system lines must have a flexible connection
between the “hard piping” and the valve.
!
CAUTION
COLOR VALVE STACK – OPERATION

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CLEANING
The valve and associated parts through which uid passes should
be cleaned after use by ushing with an appropriate solvent. While
ushing, the valve should be triggered several times in order to
ush particles from the seat and stem seal areas.
WEAR PARTS
Wear parts include the poppet seat, stem, valve needle seal, and
piston cup. All of these parts are PTFE except for the stem that is
stainless steel. Wear parts should be inspected and replaced on
a regular maintenance schedule. The frequency of replacement
depends upon cycle rate and material abrasiveness. Valves should
be inspected after six months usage. If any parts are worn, or if
paint leakage is evident, replace all wear parts with Valve Repair
Kit KK-4841.
VALVE REMOVAL
1. Disconnect air and uid lines from valve.
2. Insert the Spanner Tool (CCV-7) into one of the holes in the
spanner nut and rotate counterclockwise (as viewed from
the rear air inlet tting in valve). If the Spanner Tool is not
available, a 1-1/6-inch open-end wrench can also be used to
loosen the spanner nut.
MANIFOLD REASSEMBLY
1. When reinstalling the CCV-403-SS back into the manifold block
or valve adapter, torque the spanner nut to 132-156 lbs•in.
DO NOT OVER-TIGHTEN.
2. If the manifold blocks are disassembled, do not reuse o-ring
23165-430 which goes between each block. Replace with new
o-rings. Reusing the old o-rings may cause leakage.
3. Torque the four SS-655-ZN nuts (which hold the manifold blocks
together) to 110-130 lbs•in.
4. When reinstalling air and uid connections, use a good quality
pipe sealant on the threads. However, do not use sealant or
tape on the spanner nut threads when installing the CCV-403-
SS valve into the manifold block or valve adapter.
CCV MAINTENANCE
Refer to CS-15-01 for details.
General Problem Possible Cause Solution
DELIVERY
Fluid 1. No main supply air 1. Turn supply air on.
2. No paint connected to CCV 2. Reconnect paint.
3. Paint not pressurized 3. Check users supply.
Air (to CCV) 1. No main supply air 1. Turn supply air On.
2. Loose connection 2. Tighten connections.
LEAKAGE
Air 1. Hole in tubing 1. Replace worn tubing.
2. Loose connections 2. Tighten connections.
Fluid 1. Loose connection 1. Tighten connections.
2. Worn fluid tubing 2. Replace worn fluid tubing.
DEFICIENT DELIVERY
Air 1. Insufficient supply air 1. Check air regulator.
Fluid 1. Low supply pressure 1. Increase supply pressure.
2. Clogged or obstructed fluid lines 2. Clean or replace.
3. Clogged or obstructed CCV stack 3. Clean as required.
COLOR VALVE STACK – MAINTENANCE
COLOR VALVE STACK – TROUBLESHOOTING GUIDE

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COLOR VALVE STACK – PARTS IDENTIFICATION
Figure 5: Color Valve Stack

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COLOR VALVE STACK – PARTS IDENTIFICATION
PARTS LIST (FIGURE 5)
Item
No. Part No. Description Qty.
1 CCV-17-SS MANIFOLD BLOCK 1
2 CCV-16-SS MANIFOLD BLOCK 1
3 CCV-18-SS MANIFOLD BLOCK 1
4 CCV-403-SS COLOR VALVE ASSEMBLY TABLE A - “H”
5 CCV-37 BRACKET 2
6 SS-10022 CAP SCREW 4
7 SSF-6504 THREADED ROD (CUT TO SUIT) TABLE A - “G”
8 SS-655-ZN HEX NUT 4
9 SS-1505-CD LOCKWASHER 4
10 SSP-1421 PIPE PLUG (INCLUDED WITH VALVE ASSEMBLIES) REF.
11 Table B - “K” AIR PUSH ASSEMBLY 1
12 SSP-6427 MALE, SWIVEL ELBOW TABLE A - “H”
13 — — —
14 — — —
15 SSV-809 CHECK VALVE, 1/4” NPT, MBE, SOLVENTBORNE TABLE C - “J”
16 23165-430 O-RING TABLE A - “L”
17 ---- ---- —
18 SSP-6443 FEMALE ELBOW, 3/8” ODT X 1/4” NPT, SS TABLE D - “M”
19 LSFI0033-00 CONNECTOR, 3/8” ODT X 3/8” AN, SS 1
20 KK-4370 PLUG KIT TABLE A - “E”
21 SSP-6810 MALE TEE, 3/8” ODT X 1/4” NPT, SS TABLE D - “N”
22 SSP-6435 MALE ELBOW, 3/8” ODT X 1/4” NPT, SS TABLE D - “O”
23 SSP-6812 FEMALE TEE, 3/8” ODT X 1/4” NPT, SS TABLE D - “P”
24 — — —
25 CCV-7 VALVE TOOL (INCLUDED BUT NOT SHOWN) 1
COLOR VALVE STACK ASSEMBLY MODEL IDENTIFICATION
Check Valve Options
Model No. CCV-51 02 - 2 1 2
Air Push Valves
Fluid Inlet Fittings
# of Color Valves
Basic Part Number
Table A
Table B Table C
Table D
When ordering, use CCV-51AA-BCD as indicated by Tables A thru D.
Three characters must follow the basic part number:

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COLOR VALVE STACK – PARTS IDENTIFICATION
TABLE “A” - NUMBER OF COLOR VALVES
Dash # Description “E” “F” “G” x(4) “H” “L”
00 NO COLOR 0 0 3” 1 1
01 ONE COLOR 1 0 3” 2 1
02 TWO COLOR 0 0 3” 3 1
03 THREE COLOR 1 1 4-3/8” 4 2
04 FOUR COLOR 0 1 4-3/8” 5 2
05 FIVE COLOR 1 2 5-3/4” 6 3
06 SIX COLOR 0 2 5-3/4” 7 3
07 SEVEN COLOR 1 3 7-1/8” 8 4
08 EIGHT COLOR 0 3 7-1/8” 9 4
09 NINE COLOR 1 4 8-1/2” 10 5
10 TEN COLOR 0 4 8-1/2” 11 5
11 ELEVEN COLOR 1 5 9-7/8” 12 6
12 TWELVE COLOR 0 5 9-7/8” 13 6
13 THIRTEEN COLOR 1 6 11-1/4” 14 7
14 FOURTEEN COLOR 0 6 11-1/4” 15 7
15 FIFTEEN COLOR 1 7 12-5/8” 16 8
16 SIXTEEN COLOR 0 7 12-5/8” 17 8
17 SEVENTEEN COLOR 1 8 14” 18 9
18 EIGHTTEEN COLOR 0 8 14” 19 9
19 NINETEEN COLOR 1 9 15-3/8” 20 10
20 TWENTY COLOR 0 9 15-3/8” 21 10
21 TWENTY-ONE COLOR 1 10 16-3/4” 22 11
22 TWENTY-TWO COLOR 0 10 16-3/4” 23 11
23 TWENTY-THREE COLOR 1 11 18-1/8” 24 12
24 TWENTY-FOUR COLOR 0 11 18-1/8” 25 12
25 TWENTY-FIVE COLOR 1 12 19-1/2” 26 13
26 TWENTY-SIX COLOR 0 12 19-1/2” 27 13
27 TWENTY-SEVEN COLOR 1 13 20-7/8” 28 14
28 TWENTY-EIGHT COLOR 0 13 20-7/8” 29 14
29 TWENTY-NINE COLOR 1 14 22-1/4” 30 15
30 THIRTY COLOR 0 14 22-1/4” 31 15