Carlisle Ransburg TurboDisk A11376 User manual

EN
SERVICE MANUAL
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Model: A11376
TurboDiskTM Applicator Assembly
For Waterbase Applications

MANUAL CHANGES EN
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NOTE: ThismanualhasbeenchangedfromrevisionAA-07-02.2torevision
AA-07-02-R3. Reasons for this change are noted under “Manual
Change Summary” inside the back cover of this manual.

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CONTENTS
EN
CONTENTS
(Continued On Next Page)
SAFETY: 5-9
Safety Precautions ........................................................................................................................................................5
Hazards / Safeguards ....................................................................................................................................................6
INTRODUCTION: 10-13
Features ......................................................................................................................................................................10
General Description .....................................................................................................................................................10
Approvals .....................................................................................................................................................................11
Specications ..............................................................................................................................................................11
Typical Speed Chart (RPM’s No Load).........................................................................................................................12
Typical Speed Chart - 10 Hole Orice Plate (No Load)................................................................................................12
INSTALLATION: 14-15
Equipment...................................................................................................................................................................14
Air Control ..................................................................................................................................................................14
Mounting .....................................................................................................................................................................14
Interlocks ....................................................................................................................................................................14
Typical Layout of System ...........................................................................................................................................15
OPERATION: 16-19
Air Heater Requirements .............................................................................................................................................16
Coating Materials ........................................................................................................................................................17
Fluid Flow Control .......................................................................................................................................................17
Fluid Valve Control ......................................................................................................................................................17
Fluid and Air Pressure Requirements .........................................................................................................................17
Turbine Speed ............................................................................................................................................................18
Electrostatic Voltage ...................................................................................................................................................19
Target Distance ..........................................................................................................................................................19
MAINTENANCE: 20-30
General ........................................................................................................................................................................20
Cleaning Procedures ...................................................................................................................................................20
Vibration Noise ............................................................................................................................................................22
Turbine Repair and Rebuild .........................................................................................................................................22
Valves and Regulators ................................................................................................................................................22
Preventive Maintenance .............................................................................................................................................22
Disassembly Procedures ............................................................................................................................................23
Troubleshooting Guide ...............................................................................................................................................25
Typical Schematics .....................................................................................................................................................26
PARTS IDENTIFICATION: 31-64
A11376 TurboDisk Assembly Model Identication .......................................................................................................31
70988 Basic Systems Kit..............................................................................................................................................34

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CONTENTS EN
CONTENTS(Cont.)
PARTS IDENTIFICATION (Cont.): 31-64
TurboDisk Assemblies:
No Valves 70990-05 ..............................................................................................................................................36
3-Way Valves 70990-06 .........................................................................................................................................38
Trigger Valve Only 70990-07 .................................................................................................................................40
Trigger and Dump Valve 70990-08 ........................................................................................................................43
Trigger Valve Only with DR-1 Regulator 70990-09 ................................................................................................46
Trigger and Dump Valve with DR-1 Regulator 70990-10 .......................................................................................49
Dual DR-1 Regulator 70990-11 ..............................................................................................................................52
Drive Air Regulator 78170-00 .................................................................................................................................55
Air Heater and Regulator 78781-00 .......................................................................................................................56
Fairing 70158-00 ....................................................................................................................................................57
Air Turbine 78175-XX .............................................................................................................................................59
Turbine Cartridge 70879-XXX ................................................................................................................................61
Recommended Spare Parts .......................................................................................................................................63
Tools and Accessories ................................................................................................................................................ 64
MANUAL CHANGE SUMMARY: 65
Manual Changes .........................................................................................................................................................65

SAFETY
EN
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WARNING
!
WARNING
!
WARNING
!
CAUTION
!
NOTE
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your products. This manual contains
informationthat isimportantforyouto knowandunderstand.
ThisinformationrelatestoUSERSAFETYandPREVENTING
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 serious injury if
instructions are not followed.
A CAUTION! states information that tells how to
prevent damage to equipment or how to avoid a
situation that might cause minor injury.
A NOTE is information relevant to the procedure
in progress.
While this manual lists standard specications and service
procedures, some minor deviations may be found between
thisliteratureandyourequipment.Differencesinlocalcodes
andplantrequirements,materialdeliveryrequirements,etc.,
make such variations inevitable. Compare this manual with
yoursysteminstallationdrawingsandassociatedequipment
manuals to reconcile such differences.
The user MUST read and be familiar with the
Safety Section in this manual and the safety literature
therein identied.
This equipment is intended to be used by
trained personnel ONLY.
This manual MUST be read and thoroughly
understood by ALL personnel who operate, clean
or maintain this equipment! Special care should
be taken to ensure that the WARNINGS and safety
requirements for operating and servicing the
equipment are followed. The user should be aware
of and adhere to ALL local building and re codes
and ordinances as well as NFPA 33 AND EN 16985
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
Repairs may only be performed by personnel authorized by
Carlisle Fluid Technologies.
Carefulstudyandcontinueduse of this manual will provide a
betterunderstandingoftheequipmentandprocess,resulting
in more efcient operation, longer trouble-free service and
faster,easiertroubleshooting. Ifyoudonothavethemanuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY EN
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is. SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate operation
and maintenance procedures will
cause a re hazard.
Protection against inadvertent
arcing that is capable of causing
re or explosion is lost if any
safety interlocks are disabled
during operation. Frequent Power
Supply or Controller shutdown
indicates a problem in the system
requiring correction.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be turned off
prior to cleaning, ushing, or maintenance.
Spray booth ventilation must be kept at the rates required
by NFPA 33, EN 16985, country, and local codes. In
addition, ventilation must be maintained during cleaning
operations using ammable or combustible solvents.
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch (25mm) for
every 10KV of output voltage is required at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but only as
instructed.
Non-factory replacement parts or unauthorized
equipment modications may cause re 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.
The paint process and equipment should be set up and
operated in accordance with NFPA 33, NEC, OSHA,
local, country, and European Health and Safety Norms.
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SAFETY
EN
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is. SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate operation
and maintenance procedures will
cause a
re hazard.
Protection against inadvertent
arcing that is capable of causing
re or explosion is lost if any
safety interlocks are disabled
during operation.
Frequent Power Supply or
Controller shutdown indicates a
problem in the system requiring
correction.
Improper operation or
maintenance may create
a hazard.
Personnel must be properly
trained in the use of this
equipment.
Personnel must be given training in accordance with the
requirements of NFPA 33.
Instructions and safety precautions must be read and
understood prior to using this equipment.
Comply with appropriate local, state, and national codes
governing ventilation, re protection, operation mainte-
nance, and housekeeping. Reference OSHA, NFPA 33,
EN Norms and your insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
Electrostatic arcing must be prevented. Safe sparking
distance must be maintained between the parts being
coated and the applicator. A distance of 1 inch (25mm) for
every 10KV of output voltage is required at all times.
Unless specically approved for use in hazardous locations,
allelectricalequipmentmustbelocatedoutsideorapplicable
county code hazardous areas, in accordance with NFPA 33.
Test only in areas free of ammable or combustible materials.
The current overload sensitivity (if equipped) MUST be
set as described in the corresponding section of the
equipment manual. Protection against inadvertent arcing
that is capable of causing re or explosion is lost if the
current overload sensitivity is not properly set. Frequent
power supply shutdown indicates a problem in the system
which requires correction.
Always turn the control panel power off prior to ushing,
cleaning, or working on spray system equipment.
Before turning high voltage on, make sure no objects are
within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with NFPA-
33, EN 16985.
Have re extinguishing equipment readily available and
tested periodically.
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SAFETY EN
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is. SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A
spark can ignite many coating
materials and cause a re
or explosion.
Electrical Discharge
Parts being sprayed and operators in the spray area must be
properly grounded.
Parts being sprayed must be supported on conveyors or
hangers that are properly grounded. The resistance between
the part and earth ground must not exceed 1 Meg Ohm. (Refer
to NFPA 33, EN 16985.)
Operators must be grounded. Grounding straps on wrists or
legs may be used to assure adequate ground contact.
Footware to be used by operator shall comply with EN ISO 20344,
resistance not to exceed 100 Meg Ohm. Protective clothing
including gloves should comply with EN 1149-5, resistance not to
exceed 100 Meg Ohm.
Operators must not be wearing or carrying any ungrounded
metal objects.
When using an electrostatic handgun, operators must
assure contact with the handle of the applicator via
conductive gloves or gloves with the palm section cut out.
NOTE: REFER TO NFPA33, EN 16985 OR SPECIFIC COUN-
TRY SAFETY CODES REGARDING PROPER OPERATOR
GROUNDING.
All electrically conductive objects in the spray area, with the
exception of those objects required by the process to be at high
voltage, must be grounded. Grounded conductive ooring must
be provided in the spray area.
Always turn off the power supply prior to ushing, cleaning, or
working on spray system equipment or applicable county code.
Unless specically approved for use in hazardous locations,
all electrical equipment must be located outside or applicable
country code, hazardous areas, in accordance with NFPA 33.
Avoid installing an applicator into a uid system where the
solvent supply is ungrounded.
Do not touch the applicator electrode while it is energized.
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SAFETY
EN
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is. SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may occur.
Personnel are exposed to high
voltage during operation and
maintenance.
Protection against inadvertent arcing
that may cause a re or explosion
is lost if safety circuits are disabled
during operation.
Frequent power supply shut-down
indicates a problem in the system
which requires correction.
An electrical arc can ignite coating
materials and cause a re or
explosion.
Electrical Discharge
Electrical
Equipment
Follow the requirements of the Safety Data Sheet supplied
by coating material manufacturer.
Adequate exhaust must be provided to keep the air free of
accumulations of toxic materials. Reference EN 12215 or
applicable code.
Use a mask or respirator whenever there is a chance of
inhaling sprayed materials. The mask must be compatible
with the material being sprayed and its concentration.
Equipment must be as prescribed by an industrial hygienist
or safety expert, and be NIOSH approved.
Chemical HazardToxic
Substances Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Unless specically approved for use in hazardous locations,
the power supply, control cabinet, and all other electrical
equipment must be located outside or applicable country
codes, hazardous areas in accordance with NFPA 33 and
EN 16985.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combustible material.
Testing may require high voltage to be on, but only
as instructed.
Production should never be done with the safety
circuits disabled.
Before turning the high voltage on, make sure no objects
are within the sparking distance.
Spray applicators require that aluminum inlet ttings be
replaced with stainless steel.
Aluminum is widely used in other spray application
equipment - such as material pumps, regulators, triggering
valves, etc. Halogenated hydrocarbon solvents must
never be used with aluminum equipment during spraying,
ushing, or cleaning. Read the label or data sheet for the
material you intend to spray. If in doubt as to whether or not
a coating or cleaning material is compatible, contact your
coating supplier. Any other type of solvent may be used
with aluminum equipment.
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.
Explosion Hazard —
Incompatible Materials
Spray Area
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INTRODUCTION EN
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INTRODUCTION
FEATURES
FeatureswhichmaketheTurboDiskTMApplicatorad-
vantageousforuseinelectrostaticapplicationsinclude:
• Proven turbine motor reliability.
• Aerodynamic fairing design for ease of cleaning of
external surfaces.
• Speedreadout(orcontrol)usesreliablemagneticpickupfor
ber optic transmission of rotational speed data (optional).
• A majority of all assembly components which come in
contact with the uid material are made of stainless steel,
which is impervious to most uids.
• Negligible maintenance down time.
• The easily removable lower fairing, turbine air motor
assembly, and the externally mounted regulators and
uid valves, make off line maintenance more efcient
and economical.
• Higher uid delivery rates can be achieved using a dual
feed uid system.
• High ow regulators and uid valves provide for simul-
taneous paint push out while solvent washes the feed
tube and disk.
GENERAL DESCRIPTION
The TurboDisk Applicator, because of it's high rotational
speed, produces ner atomization, improved quality, and
higher transfer efciency with any of the wide variety of
coatingmaterials(suchaswaterborneandhighsolids)used
in production nishing operations. Its speed is controlled by
varying the drive air. The applicator assembly is designed
for use on vertical overhead mounted reciprocators.
Conical Disk Assembly
TheTurboDiskApplicator uses conical disk assemblies that
are made from high grade aluminum construction and are
Paint Valve Options
Severalvalveoptionsareavailableforbothsingleanddualfeed.
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
• Trigger Valves with DR-1 Regulator
Power Supply and Controls
In the system, the high voltage is supplied to the TurboDisk
by the MicroPak2e Industrial power supply system or a
Voltage Master™ series power supply.
The MicroPak2e Industrial power supply uses proven
high voltage generator technology that is microprocessor
controlled for diagnostics and communication.
The Voltage Master™ power supplies are general purpose
heavy duty power supplies with years of proven reliability.
They have variable voltage control, many safety features,
and remote analog voltage control capabilities.
force balanced to .10 grams•in or better. With the serrated
edge,thesediskscomeinsizesof6,9,and12inchdiameters.
TurboDisk Fairing (Refer to Figure 17)
TheTurboDisk Applicatorfairingisrequiredforsafeoperation.
The two piece fairing provides high voltage isolation from
the metal rotator assembly and valve components, as well
as ease of cleaning and maintenance. (152mm, 229mm
and 305mm)
WARNING
!
Both sections of the fairing to be in place when the
TurboDisk is in operation or when high voltage is sup-
plied to the applicator.
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INTRODUCTION
EN
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WARNING
!
APPROVALS
For end users in countries which require an ATEX
approval, the use of solvent based materials is not
permitted with this product. For applications using
waterbased materials this product is CE approved
according to the guidelines of 2006/42/EC machinery
directive. It is the end users responsibility to abide by
these requirements.
For denition of waterbase materials reference EN 50
348: ANNEX A or EN 50059: 2018 ANNEX C.
For further information reference EN 50348 for
protection requirements.
Forendusersthatdonotrequireanapprovedapplicator,
reference the applicable code requirements for safe
use. (Ref. NFPA 33)
Electrical
SPECIFICATIONS
Mechanical
Turbine Speed: Variable to 40,000 rpm max. (6-inch conical disk, 152mm)
Variable to 25,000 rpm max. (9-inch conical disk, 229mm)
Variable to 15,000 rpm max. (12-inch conical disk, 305mm)
Turbine Type: Ball Bearing
Weight: 57-lbs. (25.9 Kg) (approximately)
Length: 36-inches (915mm)
Diameter: 13.25-inches (337mm)
Turbine Air: At max. speed (40k rpm), requires 103.1 psi and 61.1 SCFM, unloaded
(See “Typical Speed Chart” in this section.) (7.1 bar and 1727 SLPM)
Air Temp °F: 120°F maximum at applicator (48.9° C)
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 (4.8 to 6.9 bar)
Air Pilot for Fluid Pressure: (See “Fluid and Air Pressure Regulator” in the “Operation” section.)
Power Supply Type: MicroPak2e Industrial or Voltage MasterTM
Charging Method: Direct
Input Voltage: 0-100 kV
Turbine Speed Control or Monitor: MicroPak 2e PulseTrack 2(Optional)
This product is NOT ATEX approved for use with
solvent based materials
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INTRODUCTION EN
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NOTE
WARNING
!
TYPICAL SPEED CHART
(RPM's NO LOAD)
(Refer to "Typical Speed Chart")
Thefollowingrepresentsdatacollectedunderlabconditions.
Flow meters were installed on each of the two 3/8-inch ID
heatedairlines used to supply theTurboDiskturbine motor.
The airow through each ow meter was recorded and added
together to obtain the total air ow through the system. The
speed of the disk was monitored through the means of a
PulseTrack system. The air heater was set at 120 degrees
during all data collection.
Never run disk over it's maximum safe operating
speed depending on disk diameter.
Air heater removes condensation from OD of mo-
tor at high speeds.
Rotational speeds are unloaded and can be expected to
drop 20 to 30% when under a uid load condition. Heated
turbine air increases efciency of motor up to 10%. This
chart should be used as a guide ONLY. Speeds will vary
due to rotator wear, tubing size or lengths, etc.
Disk Speed
(RPM) Supply Air Pressure
(PSI/BAR) Air Flow #1
(SLPM) Air Flow #2 (SLPM) Total Air Flow (SLPM) Total Air Flow (SCFM)
5,000
10,000
15,000
20,000
25,000
30,000
35,000
40,000
6.6 / 6.45
10.5 / 6.72
18.2 / 1.25
27.8 / 1.92
40.4 / 2.79
56.3 / 3.88
76.4 / 5.27
103.1 / 7.11
140
190
260
340
440
560
730
930
100
140
200
260
350
460
610
800
240
330
460
600
790
1,020
1,340
1,730
8.5
11.7
16.2
21.2
27.9
36.0
47.3
61.1
6” CONICAL DISK
Disk Speed
(RPM) Supply Air Pressure
(PSI/BAR) Air Flow #1
(SLPM) Air Flow #2 (SLPM) Total Air Flow (SLPM) Total Air Flow (SCFM)
9” CONICAL DISK
5,000
10,000
13,000
16,000
19,000
22,000
11.3 / 0.78
26 / 1.79
39.5 / 2.72
55.4 / 3.82
79.8 / 5.50
102 / 7.03
200
330
430
560
760
930
140
250
340
460
640
800
340
580
770
1,020
1,400
1,730
12.0
20.5
27.2
36.0
49.4
61.1
TYPICAL SPEED CHART - 10 HOLE
ORIFICE PLATE (NO LOAD)
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INTRODUCTION
EN
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Disk Speed
(RPM) Supply Air Pressure
(PSI/BAR) Air Flow #1
(SLPM) Air Flow #2 (SLPM) Total Air Flow (SLPM) Total Air Flow (SCFM)
12” CONICAL DISK
2,000
4,000
6,000
8,000
10,000
12,000
12,500
8.7 / 0.78
18.6 / 1.28
31.0 / 2.14
48.3 / 3.33
68.5 / 4.72
95.8 / 6.61
102.0 / 7.03
170
270
370
500
670
880
930
120
200
290
400
560
750
780
290
470
660
900
1,230
1,630
1,710
10.2
16.6
23.3
31.8
43.4
57.6
60.4
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INSTALLATION EN
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WARNING
!
WARNING
!
INSTALLATION
In waterbase applications, the isolated uid source is
charged. This charge can produce energy greater than 350
mj. It is highly recommended a ground switch be installed
to discharge this energy safely to ground.
EQUIPMENT
Thissystem shouldbe installedby,orunder thesupervision
of an Ransburg representative. Should the need arise to
replaceanycomponentassemblywithinthesystem,contact
your Ransburg representative.
This manual concerns normal operation, maintenance,
and service of the specied applicator assemblies. The
air and uid 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 Ransburg
air logic panel, which includes two lters (one 40 micron
lter located at the air logic station and one 5 micron lter
located at the inlet of the in-line air heater panel). Clean,
dry factory air must be provided to the inlet lter of the air
logic station via a minimum 1/4-inch ID pipe and to the inlet
lter of the heater panel via a minimum 3/4-inch ID pipe.
MOUNTING
(Refer to Figure 16)
The TurboDisk assembly is mounted on the reciprocator
using four (4) 5/16-18 screws provided on the ram ange.
Loosening two (2) 1/4-20 screws on the same ram ange
will allow the assembly to rotate. Position the TurboDisk
assembly so that the strain relief boot is positioned toward
the incoming uid and air lines and retighten.
Remove lower fairing. Thread all the required air, high
voltage, ber optic, and uid 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 lbs•in (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 must be spinning prior to any uid ow.
3. High voltage is on or in the bypass mode.
Voltage Interlocks
1. Highvoltagemust be interlocked withsolventvalve pilot
to prevent solvent ow while voltage is energized.
2. High voltage must be interlocked with booth or other
electricalsensingmeansthatpreventshumanentrynear
theapplicator.ReferenceEN61496-1,EN61496-2,and
EN ISO 13856-1 for further information.
Other Interlocks
1. Anyadditionalinterlocksrequiredbylocalcode,national
code, or international code.
The Air Heater Assembly must be located
outside of any hazardous areas as dened by the
NFPA-33, EN 16985.
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.
Efciency of the applicator will also be reduced and
damage or failure of the applicator components may
occur. WRAPPING THE APPLICATOR IN PLASTIC
WILL VOID WARRANTY.
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INSTALLATION
EN
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Figure 1: Typical Layout of System
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OPERATION EN
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WARNING
!
WARNING
!
CAUTION
!
OPERATION
AIR HEATER REQUIREMENTS
Turbine drive air expands as it moves through the turbine
wheel cavity and as it exits the turbine from the exhaust port.
This expansion will cause cooling of the exhaust air and the
surfaces it contacts. This 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 possible
that the temperature of the supply air may be below the
booth dew point, even without additional expansion cooling.
Condensation is especially probable in waterborne
applications when booth temperature and relative humidity
levelsaretypicallymaintainedveryhigh. Thiscondensation
will allow sufcient conductivity of the surfaces such that they
act as an erratic ground source potential. This can cause
damage to the equipment.
It is 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 that air heaters be installed into
the atomizer air supply lines, i.e. turbine drive air. The air
heaters must be of sufcient capacity, capable of raising the
incoming air temperature to at least 40°F (4.4°C) at a ow
rate of 60 SCFM per applicator.
The actual air heater process setting depends on the
applicator uid ow rate load, booth conditions, turbine
airow settings, and incoming air temperature.
The heater should be set as low as possible, sufcient to
maintaintheapplicatorsurfacetemperaturesabovethedew
point in the booth.
Example: Only with the incoming air temperature at 72°F
(22.2°C), a disk rotating unloaded at 30 krpm has a turbine
outlet temperature drop to approximately 28°F (-2.2°C) (@
40 krpm unloaded, 14°F). Referring to the ASHRAE Psy-
chrometric 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 / 65-70% RH is 16.7-20°C). Thus,
it is almost certain that the surface
As with any spray nishing system, operation of the TurboDisk
involves properly setting the operating parameters to obtain
the best nish quality for the coating material being sprayed,
while maintaining correct operation and reliability of the
equipment used. Adjustments to operating parameters,
which cover spraying, cleaning, and on/off control, include:
• Fluid Type
• Fluid Flow Rate
• Turbine Speed
• Electrostatic Voltage
• Target Distance
Fluids and lubricants used in this system must
contain NO silicones!
Do NOT operate the unit without an atomizer disk!
Without a disk, overspeed, resulting in premature
bearing failure, is possible.
The air supplied to the motor must be dry, clean,
and free of oil or moisture. The atmospheric dew point
should be 10oF (-12.2° C) or less. The air heater used
should be adjusted only high enough to prevent con-
densation from forming on the motor housing or at the
exhaust port.
Operators must be fully trained in safe operation
of electrostatic equipment. Operators must read all
instructions and safety precautions prior to using this
equipment (see NFPA-33).
DO NOT exceed the maximum ow rate of 1500
cc/min. during painting or purge cycles. Excessive u-
id ow may cause an imbalance condition and possibly
premature bearing failure.
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OPERATION
EN
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NOTE
WARNING
!
WARNING
!
COATING MATERIALS
The TurboDisk can be used with a broad range of coating
material conductivities. However, with waterborne paints, it
may be necessary to isolate the paint supply from ground.
FLUID FLOW CONTROL
Fluid ow control is dependent on the valve conguration of
the TurboDisk . If the TurboDisk is congured with no valves
or a 3-way valve, uid ow is controlled externally at the paint
source. If the TurboDisk is equipped with a regulator, uid ow
can be controlled via the air pilot signal. The high ow and
low ow regulators each have procedures on how to control
and deliver consistent uid ows. For more information on
controlling the uid delivery using regulators, refer to that
specic manual which is included with the system.
To check uid ow rates, the disk must be removed. See
the "Maintenance" section for "Removal Procedure". The
uid can then be manually triggered to measure actual ow
in a graduated beaker over a specied time period.
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 lters. (Reference the current “Air
Heater Assembly” service manual for further information.)
Failuretouseanairheatermaycausedamage
to equipment or ruin the nished component being
processed.
Isolated uid supplies using either waterborne or
highly conductive solvent base coatings can produce
hazardous high voltage discharges which can cause
res or injury to personnel.
Danger of shock and/or personal injury can occur.
Proper grounding procedures, which are outlined in the
Ransburg safety bulletins, must be followed. Personnel
must never work near or perform work on the turbine
when the turbine is spinning or when high voltage is on.
FLUID VALVE CONTROL
Trigger and Dump (Refer to "TurboDisk
Fluid and Air Pressure Requirements")
The uid valves in the TurboDisk are actuated by an air
signal. The air pressure must exceed 70 psi to assure proper
actuationofthevalve.Applyingairtothevalveactuatorturns
on the uid ow for that valve.
The trigger valve controls the paint ow to the disk. When
actuated, paint ows through the valve to the uid tube.
The disk should be spinning at an rpm speed that is fast
enough, (that when uid is turned on) to enable the uid to
ow through the disk paint passage holes and be atomized.
The dump valve controls the paint ow through the dump
line. When actuated, paint ow is directed to the dump return
line. This provides a method of rapidly removing paint from
theincominglineforcleaningand/orcolorchange.Normally,
thedumpvalveisnotactuatedatthesametimeasthepaint
trigger valve since the trigger valve is intended to cause the
uid ow to the disk at the prescribed input pressure.
FLUID AND AIR PRESSURE
REQUIREMENTS
(Refer to "TurboDisk Fluid and Air Pressure
Requirements")
Fluid and air pressure requirements are dependent on the
uid trigger valve conguration.
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OPERATION EN
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NOTE
WARNING
!
WARNING
!
WARNING
!
Note: Trigger/dump valves (CCV-403-SS) are rated to 300 psi maximum inlet uid pressure but are limited to the lower pressure limit
of the uid regulators.
Air Pilot Fluid Regulator --- --- 100 psi max. 100 psi
Air Inlet Trigger/Dump Valve --- 120 psi max. 70-100 psi 70-100 psi
Fluid Inlet Pressure --- 300 psi max. 80-100 psi max. 80-100 psi max.
Solvent Inlet --- 30-60 psi max. 30-60 psi max. 30-60 psi max.
3-Way ON/OFF
(18283)
No
Valves Trigger/Dump W/High Flow (70171-04) Regulator Trigger/Dump W/Low Flow
DR-1 (74151) Regulator
TURBINE SPEED
Turbine speed is determined by the driveairpressureatthe
rotary atomizer and uid ow rate.
Turbine speed can be closed loop controlled using the ber
optic speed transmitter mounted at the back of the turbine
rotator assembly as a speed input to remote speed controls
such as the PulseTrack 2.
Atomizers
(Refer to "Typical Maximum Safe Operating Speeds")
All atomizers manufactured after April 6, 1982, bear a “K”
number. That number indicates 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 Ransburg representative for its maximum safe
operating speed.
The disk rotational speed determines the quality of
atomization and can be varied for different ow rates and
viscosities. For optimum transfer efciency and spray pat-
terncontrol,thediskrotationalspeedshouldbesetatthe
minimum required speed to achieve proper atomization.
Excessive speed reduces transfer efciency!
Do not 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 uid delivery is stopped. Damage to persons
or equipment may result from over-speed conditions.
Never operate any disk atomizer in excess of it's
maximum rated speed ("K" number) as listed in the ser-
vice manual. Excessive speed may cause the disk to
disintegrate, causing serious damage and/or injury.
Inspectdiskplatterdailyforwearordamage.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 FLUID AND AIR PRESSURE REQUIREMENTS
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OPERATION
EN
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ELECTROSTATIC VOLTAGE
In the system, the high voltage is supplied to the TurboDisk
byeithertheMicroPak/MicroPak2eIndustrialpowersupply
system or Voltage Master series power supplies.
The MicroPak/MicroPak2e industrial power supply
uses proven high voltage generator technology that
is microprocessor controlled for diagnostics and
communication. The controller is packaged in standard
rack mounted Eurocard format for easy access and system
integration.
The Voltage Master power supplies are general purpose
heavy duty power supplies with years of proven reliability.
They have variable voltage control, many safety features,
and remote analog voltage control capabilities.
TARGET DISTANCE
The distance between the TurboDisk and the target will
affect the nish quality, penetration, and efciency. Closer
distances give wetter nishes and greater efciency, while
greater distances give drier nishes. The recommended
normal disk edge to target range is 12-inches (305mm)
minimum for optimum performance.
Disk Type Part Number
TYPICAL MAXIMUM SAFE OPERATING SPEEDS
Max. RPM
None --- ---
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 20485-125 15,000
Uni-Disk Assy., 6", Aluminum, Not Anodized 19830-06 27,000
Uni-Disk Assy., 8", Aluminum, Not Anodized 19830-08 23,000
Uni-Disk Assy., 10", Aluminum, Not Anodized 19830-10 15,000
Uni-Disk Assy., 12", Aluminum, Not Anodized 19830-12 15,000
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MAINTENANCE EN
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WARNING
!
WARNING
!
WARNING
!
WARNING
!
WARNING
!
CAUTION
!
MAINTENANCE
GENERAL
Verify daily that the operating parameters have not varied
dramatically. A sudden change or even a gradual decay in
performancecouldbeearlyindicationsofcomponentfailure.
Normalmaintenanceproceduresshouldbeestablishedand
recorded at the initial start-up. All maintenance schedules
are subject to variation based on use. Periodically review
these maintenance schedules as equipment ages and
needs change.
CLEANING PROCEDURES
In addition to the above Warning, which relates to potential
safety hazards, the following information must be observed
to prevent damage to the equipment.
Electrical shock and re hazards can exist during
maintenance. The power supply must be turned off be-
fore entering the spray area. Spray booth fans should
remain on while cleaning with solvents.
Never touch the disk atomizer while it is spinning.
The edge of the disk can easily cut into human skin,
gloves or other materials. 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 four minutes.
Do not immerse the TurboDisk assembly in solvent
or other liquids. Turbine components will be damaged.
Do not soak the disk in solvent longer than 24 hours.
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.
Efciency of the applicator will also be reduced and
damage or failure of the applicator components may
occur. WRAPPING THE APPLICATOR IN PLASTIC
WILL VOID WARRANTY.
Inspect disk platter daily for wear or damage. Re-
place 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.
Internal Fluid Path Cleaning
With the high voltage turned off and the disk spinning, ush
cleaningsolvent through theincom-ingpaint lineorthrough
the solvent inlet line. If it is desired to clean just the face
of the disk off, ush solvent through the solvent inlet. If
a color change is required, ush the entire system. The
spinningdiskwill atomize the solventandcleanout the disk
passages. If equipped, trigger the dump valve to catch the
wasted paint from the incoming line, then ush the disk with
solvent after closing the dump valve.
Never submerge a disk into a solvent bath while
still mounted on the shaft. Solvent may intrude into
bearing cavity and destroy the grease. Remove disk
to hand clean or run disk and ush through trigger and
dump valves.
CAUTION
!
Because of the hazard of bearing penetration, sol-
vents should be used sparingly! They should NEVER
be hosed directly onto the atomizer, motor housing, or
any ber optic juncture.
Prior to servicing ensure all voltage has been dis-
charged to ground. For waterbase applications ensure
all voltage is discharged to ground either by waiting for
all voltage to decay (depend on installation) or use a
ground switch installed in the system.
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