Ransburg A11065-05 User manual

SERVICE MANUAL
LN-9245-00.8
(Replaces LN-9245-00.7)
May - 2013
AIR HEATER ASSEMBLY
MODEL: A11065-05
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: $20.00 (U.S.)

NOTE: This manual has been changed from revision LN-9245-00.7 to revision LN-9245-00.8
Reasons for this change are noted under “Manual Change Summary” are on page 23
of this manual.
Air Heater Assembly - Safety
LN-9245-00.8

SAFETY:
SAFETY PRECAUTIONS............................................................................................................
HAZARDS / SAFEGUARDS........................................................................................................
PAGE
INTRODUCTION:
CONTENTS
GENERAL DESCRIPTION..........................................................................................................
FEATURES AND BENEFITS......................................................................................................
SPECIFICATIONS.......................................................................................................................
INSTALLATION:
LOCATION...................................................................................................................................
INPUT POWER............................................................................................................................
PNEUMATIC CONNECTIONS...................................................................................................
INSTALLATION OPTIONS..........................................................................................................
FRONT PANEL DISPLAY AND FUNCTIONS...........................................................................
OPERATION:
PRINCIPLES OF OPERATION...................................................................................................
WIRING DIAGRAM SCHEMATIC...............................................................................................
POWER AND CONTROL WIRING DIAGRAM..........................................................................
START-UP....................................................................................................................................
1-5
6-7
8-12
13-16
1
2-5
6
6
7
8
8
8-9
9-10
11-12
13
14
15
16
PARTS IDENTIFICATION:
A110065-05 AIR HEATER ASSEMBLY / PARTS LIST..............................................................
ACCESSORIES...........................................................................................................................
19-20
19-20
20
WARRANTY POLICIES: 21
LIMITED WARRANTY..................................................................................................................21
MAINTENANCE:
HEATER REMOVAL....................................................................................................................
TROUBLESHOOTING GUIDE....................................................................................................
17-18
17
18
Air Heater Assembly - Safety
LN-9245-00.8

W A R N I N G
!
W A R N I N G
!
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety literature
for your Ransburg products.This manual contains
information that is important for you to know and
understand. This information relates to USER
SAFETY and PREVENTING EQUIPMENTPROB-
LEMS. 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 proce-
dure in progress.
While this manual lists standard specications
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 draw-
ings and appropriate Ransburg equipment man-
uals to reconcile such differences.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efcient opera-
tion, longer trouble-free service and faster, easier
troubleshooting. If you do not have the manuals
and safety literature for your Ransburg system,
contact your local Ransburg representative or
Ransburg.
The hazards shown on the following pag-
es may occur during the normal use of this
equipment. Please read the hazard chart be-
ginning on page 2.
The user MUST read and be familiar with
the Safety Section in this manual and the
Ransburg safety literature therein identied.
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
adhere to ALL local building and re codes
and ordinances as well as NFPA-33 SAFE-
TY STANDARD, LATEST EDITION, prior
to installing, operating, and/or servicing this
equipment.
Air Heater Assembly - Safety
1LN-9245-00.8

Spray Area
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadver-
tent arcing that is capable of
causing re or explosion is
lost if any safety interlocks
are disabled during opera-
tion. Frequent Power Supply
or Controller shutdown indi-
cates 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 main-
tenance.
When using solvents for cleaning:
•Those used for equipment ushing should
have ash points equal to or higher than
those of the coating material.
•Those used for general cleaning must have
ash points above 100°F (37.8°C).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, country, and local
codes. In addition, ventilation must be main-
tained during cleaning operations using am-
mable or combustible solvents.
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A dis-
tance of 1 inch for every 10KV of output voltage
is required at all times.
Test only in areas free of combustible material.
Testing may require high voltage to be on, but
only as instructed.
Non-factory replacement parts or unauthor-
ized 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 dis-
abled.
Never use equipment intended for use in water-
borne installations to spray solvent based ma-
terials.
Air Heater Assembly - Safety
2
LN-9245-00.8

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area
Improper operation or mainte-
nance may create a hazard.
Personnel must be properly
trained in the use of this equip-
ment.
Explosion Hazard
Improper or inadequate opera-
tion and maintenance proce-
dures will cause a re hazard.
Protection against inadvertent
arcing that is capable of caus-
ing re or explosion is lost if
any safety interlocks are dis-
abled during operation.
Frequent Power Supply or
Controller shutdown indicates
a problem in the system requir-
ing correction.
General Use and
Maintenance
Electrostatic arcing must be prevented. Safe
sparking distance must be maintained between
the parts being coated and the applicator. A dis-
tance of 1 inch for every 10KV of output voltage
is required at all times.
Unless specically approved for use in hazard-
ous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2
hazardous areas, in accordance with NFPA-33.
Test only in areas free of ammable or combus-
tible materials.
The current overload sensitivity (if equipped)
MUST be set as described in the correspond-
ing section of the equipment manual. Protec-
tion against inadvertent arcing that is capable
of causing re or explosion is lost if the current
overload sensitivity is not properly set. Fre-
quent power supply shutdown indicates a prob-
lem 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 accor-
dance with NFPA-33, EN 50176.
Have re extinguishing equipment readily avail-
able and tested periodically.
Personnel must be given training in accordance
with the requirements of NFPA-33, EN 60079-0.
Instructions and safety precautions must be
read and understood prior to using this equip-
ment.
Comply with appropriate local, state, and na-
tional codes governing ventilation, re protec-
tion, operation maintenance, and housekeep-
ing. Reference OSHA, NFPA-33, EN Norms
and your insurance company requirements.
Air Heater Assembly - Safety
3LN-9245-00.8

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
Electrical Discharge
There is a high voltage device
that can induce an electrical
charge on ungrounded objects
which is capable of igniting
coating materials.
Inadequate grounding will
cause a spark hazard. A spark
can ignite many coating materi-
als and cause a re or explo-
sion.
Parts being sprayed and operators in the spray
area must be properly grounded.
Parts being sprayed must be supported on con-
veyors or hangers that are properly grounded.
The resistance between the part and earth
ground must not exceed 1 meg ohm. (Refer to
NFPA-33.)
Operators must be grounded. Rubber soled in-
sulating shoes should not be worn. Grounding
straps on wrists or legs may be used to assure
adequate ground contact.
Operators must not be wearing or carrying any
ungrounded metal objects.
When using an electrostatic handgun, operators
must assure contact with the handle of the ap-
plicator via conductive gloves or gloves with the
palm section cut out.
NOTE: REFER TO NFPA-33 OR SPECIFIC
COUNTRY SAFETY CODES REGARDING
PROPER OPERATOR GROUNDING.
All electrically conductive objects in the spray
area, with the exception of those objects re-
quired 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 ush-
ing, cleaning, or working on spray system equip-
ment.
Unless specically approved for use in hazard-
ous locations, all electrical equipment must be
located outside Class I or II, Division 1 or 2 haz-
ardous areas, in accordance with NFPA-33.
Air Heater Assembly - Safety
4
LN-9245-00.8

Toxic Substances Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manu-
facturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Electrical
Equipment
Electrical Discharge
High voltage equipment is uti-
lized in the process. Arcing
in the vicinity of ammable or
combustible materials may oc-
cur. 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 correc-
tion.
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
Unless specically approved for use in hazard-
ous locations, the power supply, control cabinet,
and all other electrical equipment must be locat-
ed outside Class I or II, Division 1 and 2 hazard-
ous areas in accordance with NFPA-33 and EN
50176.
Turn the power supply OFF before working on
the equipment.
Test only in areas free of ammable or combus-
tible 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.
Explosion Hazard –
Incompatible Materials
Halogenated hydrocarbon sol-
vents for example: methylene
chloride and 1,1,1,-Trichloro-
ethane are not chemically com-
patible with the aluminum that
might be used in many system
components. The chemical
reaction caused by these sol-
vents reacting with aluminum
can become violent and lead to
an equipment explosion.
Aluminum is widely used in other spray ap-
plication 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.
Spray Area
Air Heater Assembly - Safety
5LN-9245-00.8

GENERAL DESCRIPTION
In automated nishing applications, the expansion
of pressurized air causes cooling which may result
in condensation on surfaces of electrostatic ap-
plicators. The Ransburg Air Heater Assembly is
designed to reduce or eliminate condensation that
may form in or on the Ransburg TurboDisk and
RotaryAtomizers, or other pressurized applicators
under certain operating conditions.
Ambient temperature and relative humidity in most
installations is hard to maintain. The Air Heater
Assembly is designed to maintain the temperature
of your operating air supply to ensure no moisture
or condensation will occur on/in the applicator or
its feed or exhaust lines. This helps reduce high
voltage faults and rejected parts due to excess
moisture issues.
FEATURES AND
BENEFITS
• Heats up quickly and accurately - Allows
system users to ramp up production in a mini-
mum of time.
• Self contained - Small, compact cabinet fea-
tures plug'n play components making it easy
to t into existing systems or add into planned
system designs.
• Cabinet is "touch-safe" - Exterior of the
heater is cool to the touch.
• Precision control - Provides users with ac-
curate temperature feedback via audible and
visual displays and alarms.
• Heats drive-air to optimum temperature
INTRODUCTION
- Heats as required to keep rotator housing
warm enough to prevent condensation by
maintaining exhaust temperatures above the
dew point.
• The actual heater process setting depends on
applicator uid ow rate, booth conditions, air
ow, inlet and ambient air temperatures. The
heater should be set as low as possible, sufcient
to maintain the applicator surface temperatures
above the dewpoint of the booth environment.
Air Heater Assembly - Introduction
6
LN-9245-00.8

SPECIFICATIONS
Dimensions:
16.5-inch H X 10.31-inch W X 5.5-inch D
41.91 cm H X 26.18 cm W X 13.97 cm D
Weight: 23 lbs./10.43 kilograms
Air Inlet & Outlet: 1/2-inch NPT Pipe Thread
Environmental / Physical
Input/Dual Voltage: 120/240 VAC + 10%/15
amps/50-60 hertz Single
Phase (J1 / J2 jumpers
prewired @ 240 VAC)
Electrical
Air Supply
Pressure: 150 psi (1034 kPa)
maximum
Air Flow: 1 SCFM (141.6 SLPM)
minimum
60 SCFM maximum
(1699.0 Liter/minimum)
Filtration: 50 micron
(Additional ltration may be
required depending on
applicator used. Refer to
an "Applicator Manual" for
required ltration.)
Air Temperature
Output Range: 50°F to 150°F
(10°C to 66°C)
Mounting Location :Non-hazardous location
Mechanical
Air Flow and Pressure Drop
Comparisons
Air Heater Assembly - Introduction
7LN-9245-00.8

LOCATION
INSTALLATION
Install the air heater near the applicator, but in an
area outside of the hazardous location. The unit
should be located so that it is not exposed to water,
paints or solvents, and high temperatures. (The
ambient temperature should not exceed 120°F.)
INPUT POWER
Input supply voltage connection should be made
from a fused disconnect. Route the input power
wires through the side of the cabinet. Generally,
conduit should be used for the input power. (Always
comply with national and local electrical codes.)
PNEUMATIC
CONNECTIONS
Use appropriate size piping to connect the air
heater to a ltered inlet source. The air heater
compressed air input is at the bottom of the unit
and is identied as "IN". Connect the heated air
output located at the top of the unit identied as
"hot outlet pipe" to the coating applicator(s) using
1/2-inch OD, nylon 11/12-inch tubing, with proper
pressure rating.
Asecondary sensing air supply must be connected
to the pressure switch [8] through 1/4-inch OD
tube tting [29].
If the unit is being wired directly to the PLC elec-
trical connections, the pressure switch must be
by-passed. (Refer to "Figure 1: Installation Op-
tions" for assistance.)
> The air heater cabinet must be prop-
erly connected to earth ground.
W A R N I N G
!
> Do not locate the unit near or adjacent
to heat producing equipment such as
oven, high wattage lamps, steam pipes,
etc.
C A U T I O N
!
> The air heater MUST be located out-
side of any hazardous area(s) as close
to applicator as possible. (See NFPA-
33.)
> This manual must be read and thor-
oughly understood by ALL personnel who
operate, clean, or maintain this equip-
ment. Special care should be taken to
ensure that the WARNINGS and require-
ments for operating and servicing are
safely followed.
W A R N I N G
!
> All hardware and tubing used be-
tween the air heater and applicator must
have proper working pressure (150 psig)
and temperature (150°F) ratings.
W A R N I N G
!
Air Heater Assembly - Installation
8
LN-9245-00.8

> Recommended air ltration for the air
heater is 50 micron and must be free of
oil. Additional ltration may be required
depending on applicator used. (Refer to
Applicator manual for required ltration.)
NOTE
> DO NOT operate air heater without a
minimum of 1 SCFM of air ow through
the unit.
W A R N I N G
!
INSTALLATION OPTIONS
(See Figure 1)
Heater Pressure Switch Interlock Options for
Activation:
1. Pilot from one of the following items which
corresponds and signals air is owing:
a. Volume booster - requires a minimum of 1
psig.
b. PLC pneumatic output - requires a mini-
mum of 1 psig.
c. Air regulator - requires a minimum of 1 psig.
2. Directly from a remote electrical control (such
> Never activate heater without air ow.
C A U T I O N
!
as a turbine speed control or PLC). This contact
must correspond and signal that air is owing
through the heater.
This electrical circuit must be connected using a
minimum 1 amp dry contact relay (such as PLC
contact). This can be completed by the following:
1. Remove the present wire from TB8-1.
2. Using a wire nut, connect the wire removed in
step 1 to a longer wire and route to one side of
the remote contact.
3. Run a wire from the other side of the remote
contact back to TB8-1.
4. Add pressure switch changes, A1.
When the remote contact is closed, the air heater
will turn on.
Air Heater Assembly - Installation
9LN-9245-00.8

Figure 1: Installation Options
Air Heater Assembly - Installation
10
LN-9245-00.8

> Air lters must be located before the
air heater. Heated air may damage air
lters.
> The use of an in-line lubricator before
the air heater is NOT recommended. Oil
laden air passing across the heating ele-
ments results in burnt contaminates which
will accumulate and plug applicator ports.
This action may cause premature atom-
izer turbine failure.
>It is the user's responsibility to
ensure clean air at all times. Failures
resulting from contaminated air will
not be covered under warranty.
C A U T I O N
!
FRONT PANEL DISPLAY AND FUNCTIONS
FUJI MICRO CONTROLLER "X", MODEL PXG4
Air Heater Assembly - Installation
11 LN-9245-00.8

> Expect alarm light to ash when auto
tuning.
NOTE
USER Key
Press this key in monitoring mode display or setup
mode display returns you to the PV/SV display.
Pressing this key on the PV/SV display allows
you to set the function for uTey under the system
menu (5Y5 Ch 7). (The factory set function for
this key is switching between auto and manual.)
SEL Key
Switches the PV/SV display to the monitoring
mode display or setup mode display. Switches
to setup mode when parameter display and this
key functions as the select key when changing
parameters. Holding this key down in channel
display or parameter display returns you to the
PV/SV display. Pressing this key at PV/SV display
in manual mode, manual output value is shown
in the lower display.
Key
Pressing once will increase the setting value by
one. Holding down the button will continue to
increase the value. It changes SV on the PV/
SV display. It is also used to move between
items in channel screen display and parameter
screen display.
Key
Pressing once will decrease the setting value
by one. Holding down the button will continue
to decrease the value. It changes SV on the
PV/SV display. It is also used to move between
items in channel screen display and parameter
screen display.
OPERATION PARTS
Display
C1/C2 Lamp
Displays the condition of the control output. Lights
ON at 100% output and goes out at 0% output.
For values between 0% and 100%, the output is
indicated by the length of time the lamp ickers.
When acting as a valve control, the C1 lamp will
light with OPEN output, and the CS lamp will icker
with CLOSE output.
DO1/2/3 Lamp
Lights ON when there is digital output is on state
(DO1, DO2, DO3). The lamp ickers when delay
behavior is on.
PV Display
Displays the measurement value (PV). Displays
the name of the parameter when setting param eters.
SV Display
Displays the set value (SV). Also can display the
output value during manual mode. Displays the
parameter setting value when setting parameters.
Displays (rEN) during remote SV operation and
5oFRand set value alternately during soft start.
SV Lamp
Lights when displaying the set value (SV). Goes
out when displaying the manual output value. The
lamp ickers while performing ramp soak or lamp
SV operations.
MAN/AT/SELF Lamp
Normally lights up during manual mode and blinks
during auto-tuning or self-tuning.
DISPLAY
Air Heater Assembly - Installation
12
LN-9245-00.8

OPERATION
PRINCIPLES OF
OPERATION
The Air Heater system is shipped as 230V/
1 phase 50/60 Hz operation but can be converted
with simple jumper changes to 115 volt operation.
Heater and controls are contained in a single,
steel Type 12 enclosure vented to the atmosphere
through access ports for compressed air delivery.
Three LED indicator lights indicate the status of the
system. Green indicates a "power on" condition.
Red indicates an "alarm condition" resulting in
shutdown of power to the heater. Amber indicates
"insufcient air ow" for safe operation. The red
or amber light remains steady when ON or can be
jumper selected to ash when ON. In addition, an
audible warning option is also jumper selectable
to sound in intermittent warning when either the
red or the amber light is lit.
If an alarm condition occurs such as high tempera-
ture or insufcient air ow, the power to the heater
is interrupted by the safety contactor. When the
alarm condition is removed by the heater cooling
off or the airow increasing, the heater will be
energized and operate until the system is turned
off or the next alarm condition occurs.
The heart of the control process is the temperature
controller. Upon startup, or immediately follow-
ing the acknowledgement of any alarm condi-
tion, the controller's PID programming provides
a fast, smooth approach to the nal temperature
set- point. The PID parameter is set per "Auto-
Tuning Procedure" (see "Controller" manual for
"Auto-Tuning Procedure and all detailed controller
functions").
No cooling is required for the system. Air ow of
at least one (1) SCFM (28.3 SLPM) will satisfy
heater needs.
NOTES
Air Heater Assembly - Operation
13 LN-9245-00.8

Figure 2: Wiring Diagram Schematic
Air Heater Assembly - Operation
14
LN-9245-00.8

Figure 3: Power And Control Wiring Diagram
Air Heater Assembly - Operation
15 LN-9245-00.8

START-UP
1. Apply main power to unit.
2. Turn on and set air at a minimum of 1 SCFM
with a pneumatic pilot signal to the pressure switch
of at least 1 psig.
3. Adjust temperature to desired setting using
the key pad on face panel (maximum setting is
150°F).
> Heating the drive-air to between
120°F and 140°F will usually keep the
rotator housing warm enough to prevent
condensation. Use ONLY enough heat to
prevent moisture buildup!
NOTE
> When turning the air heater off, rst
remove power and allow the unit to cool
prior to turning off air ow. Failure to do
so may create excessive heat in the heat-
ing element and may cause permanent
damage or reduced service life of heating
element.
C A U T I O N
!
NOTES
4. The unit is now ready for normal operation.
Air Heater Assembly - Operation
16
LN-9245-00.8

MAINTENANCE
HEATER REMOVAL
When removing the heater from the system,
assure the following:
• The air supply is off and locked out.
• Main supply power is off and locked out.
• The heating element section, attached ttings,
and tubing are cool enough to touch.
NOTES
Air Heater Assembly - Maintenance
17 LN-9245-00.8