Ransburg - Carlisle Fluid Technologies · Always turn the control panel off prior to flushing,...

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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.

MODEL: 74644

PRODUCT MANUAL

LN-9404-00.3

Fluid Metering Pump

Ransburg

2

NOTES

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Section 1: SAFETY

Safety Precautions

Hazards / Safeguards

Section 2: INTRODUCTION

General Description

Specifications

Section 3: INSTALLATION

Alignment Procedure

Relief valve Kit

Section 4: OPERATION

General Operation

Section 5: MAINTENANCE

Troubleshooting

Section 6: PARTS IDENTIFICATION

Fluid Pressure Relief Valve

Section 7: CHANGE LOG

Changes

Section 8: APPENDIX

Warranty Policies

CONTENTS

LN-9404-00.3 : 74644 Fluid Metering Pump

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5-8

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Section 1: SAFETY


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 PRE-VENTING EQUIPMENT PROBLEMS. To help you rec-ognize this information, we use the following symbols:

CAUTION - states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury.

WARNING - states information to alert you to a situation that might cause serious injury if instructions are not followed.

• The user MUST read and be familiar with the Safety Section in this manual and the Ransburg safety literature therein identified.

• 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 re-quirements for operating and servicing the equipment are followed. The user should be aware of and adhere to ALL local building and fire codes and ordinances as well as NFPA 33 SAFETY STANDARD, 2009 EDITION, prior to installing, operating, and/or servicing this equipment.

• The hazards shown on the following pages may occur during normal use of this equipment. Please read the hazard chart beginning on page 6.

WARNING

While this manual lists standard specifications and ser-vice procedures, some minor deviations may be found between the 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 manuals 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 efficient operation, longer trou-ble-free service and faster, easier troubleshooting. If you do not have the manuals and safety literature for your Ransburg system, contact your local Ransburg represen-tative or Ransburg.

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Spray Area Fire Hazard

Improper or inadequate operation and maintenance procedures will cause a fire hazard.

Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation. Frequent power supply shut-down indicates a problem in the system requiring correction.

Follow These Guidelines

Fire extinguishing equipment must be present in the spray area and test 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, flushing or main-tenance.

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 1000F (37.80C).

Spray booth ventilation must be kept at the rates required by NFPA 33, 2009 Edition, OSHA and local codes. Ventilation must be maintained during cleaning operations using flammable or combustible solvents.

Electrostatic arcing must be prevented.

Non-factory replacement parts or unauthorized equipment modifications may cause fire or injury.

If used, a key switch bypass is intended for use only during setup operations. Production should never be done with safety interlocks disabled.

Never use equipment for use in waterborne installations to spray solvent based materials.

AREA HAZARD SAFEGUARDS

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Spray Area Explosion

Improper or inadequate operation and maintenance procedures may cause an explosion.

Protection against inadvertent arcing that is capable of causing fire or explosion is lost if any safety interlocks are disabled during operation. Frequent power supply shut-down indicates a problem in the system requiring correction.


Electrostatic arcing MUST be prevented.

All electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA 33, 2009 Edition.

Test only in areas free of flammable or combustible materials.

The current overload sensitivity (if equipped) MUST be set as described in corresponding section of the equipment manual. Protection against inadvertent arc-ing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set. Frequent power shutdown indicates a problem with the system which requires correction.

Always turn the control panel off prior to flushing, cleaning, or working on spray system equipment.

Ensure that the control panel is interlocked with the ventilation system and conveyor in accordance with NFPA 33, 2009 Edition.

Have fire extinguishing equipment readily available and tested periodically.

Explosion - Incompatible Materials

Halogenated hydrocarbon solvents for example: methylene chloride and 1,1,1,-Tri-chloroethane 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.

Spray Area Follow These Guidelines

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 not a coating or cleaning material is com-patible, contact your coating supplier. Any other type of solvent may be used with aluminum equipment.


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Spray Area / High Volt-age 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 materials and cause a fire or explosion.


Parts being sprayed must be supported on conveyors or hangers and be grounded. The resistance between the part and ground must not exceed 1 mega ohm.

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.

Any person working in the spray area must be ground-ed.

Unless specifically approved for use in hazardous locations, the power supply and other electrical control equipment must NOT be used in Class I, Division 1 or 2 locations.

Electrical Discharge

High voltage equipment is utilized. Arcing in areas of flammable or combustible mate-rials may occur. Personnel are exposed to high voltage during operation and mainte-nance.

Protection against inadvertent arcing that may cause a fire or explosion is lost if safe-ty circuits are disabled during operation.

Frequent power supply shutdown indicates a problem in the system which requires correction.

An electrical arc can ignite coating materi-als and cause a fire or explosion.

Electrical Equipment Follow These Guidelines

All electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas. Refer to NFPA 33, 2009 Edition.

Turn the power supply OFF before working on the equipment.

Test only in areas free of flammable or combustible material.

Testing may require high voltage to be on, but only as instructed.

Production should never be done with the safety cir-cuits disabled.

Before turning the high voltage on, make sure no ob-jects are within the sparking distance.


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Robot Work Area Mechanical Hazard

Improper use or maintenance can lead to hazardous conditions, particularly from unexpected robot manipulator movement.


Applicator adjustments or maintenance should be done after the robot is taken out of service. Do not adjust or repair the applicator if the robot is operating or standing ready to start.

Refer to robot operating instructions for the procedures to take a robot out of service.

Follow all OSHA Lockout / Tagout procedures when performing any maintenance.

Improper / Inadequate Training

Improper operation or maintenance may create a hazard.

Personnel must be properly trained in the use of this equipment.

All Areas Follow These Guidelines

Personnel must be given training in accordance with the requirements of NFPA 33, 2009 Edition.

Instructions and safety precautions must understood prior to using this equipment.

Comply with appropriate codes governing ventilation, fire protection, operation maintenance, and house-keeping. OSHA references are sections 1910.94 and 1910.107. Also refer to NFPA 33, 2009 Edition and your insurance company requirements.

Toxic Substances Mechanical Hazard

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 the coating manufacturer.

Adequate exhaust must be provided to keep the air free of accumulations of toxic materials.

Use a mask or respirator whenever there is a chance of inhaling sprayed materials. The mask must be compatible with the material being sprayed and its concentration. Equipment must be as prescribed by an industrial hygienist or safety expert, and be NIOSH approved.


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General Description

The Ransburg 74644 Fluid Metering Pump is a positive displacement pump designed to withstand the pressure needed to move highly viscous material to an applicator. It may be used effectively with any type of low pressure supply system. It’s ability to handle pressure up to 60 psi (4.2 kg/cm2) makes it especially well suited for use with automatic color change equipment as used with bell or disk applicators. The 74644 pump is easily integrated with present drive mounting and gear arrangements.

Two models of pump are available:

74644-03 — Ceramic Mechanical Seal

Choose this pump for acid based and etching coatings

74644-40 — Automatic Adjusting Packed Seal

Standard pump used with most solvent and water based coatings.

Environmental / PhysicalHeight:

Width:

MechanicalDrive Shaft Size:

Maximum Torque:

Maximum Flow:

Specifications

7 1/2 inches

2 3/4 inches

.500/.499 inch

28 lbs-in

.5 GPM (1833 cc/min) @ 1800

RPM

Section 2: INTRODUCTION

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Section 3: INSTALLATION


1. Place the pump in position to engage the spur gear.

2. Finger tighten the pump mounting bolts.

3. Hand rotate the gears. They should turn freely. Gear teeth should have .020 inches (0.5 mm) clearance.

4. Secure the mounting bolts.

5. Check the rotation. If it is not smooth, loosen and re-adjust the unit.

6. A small quantity of silicone free gear lubricant may be used on the gears to help quiet and lubricate. gears.

DC Drive PumpAlignment Procedure

CAUTIONImproper gear lash adjustment will put undue side load stresses on the pump

seal, resulting in premature failure.

.020

NOTE

The pump operates with flow in either direction of rotation.

Fluid Flow is in the direction of rotation.

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DDP Pump

Alignment Procedure

The DDP Pump utilizes a Lovejoy type coupling. Love Joy couplings are designed to absorb some vibration and misalignment, but should still be periodically checked for proper alignment.

Parallel alignment

Love Joy couplings have a built in spacing feature. Raised dots on each side of the cushion give the correct pre-measured gap between the jaw and body.

Align couplings so that a straight edge rests squarely or within .008” on hubs. See “A” dimension on figure 4. Check with a feeler gage. The clearance at “A” must not exceed the offset limit of .008”. Repeat procedure at 90°intervals.

Angular Alignment

To check the angular alignment, measure space “B” (Figure 4) with a feeler gage. Next measure the space 180° from “B” at “B1”. This space should measure the same as “B” within ±.005” . Repeat the above at 90° intervals. This procedure will limit the angular misalignment within 1°.

FIGURE 3

Lovejoy Cushion

B1

A

FIGURE 4

LOVE JOY COUPLING

STRAIGHT EDGE

B

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RELIEF VALVE KITA relief valve kit must be installed to prevent back pressure from causing a rupture or leak. A relief valve kit (A12577-00) is available as a replacement or new relief valve, but is NOT included with the 74644 pump. The A12577-00 has a 65 psi relief pressure.

RELIEF VALVE KIT INSTALLATION

To install kit onto pump, proceed as follows (see fig 1.):

1. Remove two (2) adapters (item 1.2 and 2.3) from the two sub-assemblies. Use adhesive tape ( or equivalent sealant) on the threads of the adapter. Install adapters into “IN” and “OUT” ports of pump.

2. Determine which port is the fluid outlet and install the relief valve sub-assembly (item 2) into that port. Tighten swivel while holding sub-assembly with valve in the direction shown in figure 1. Valve must never be allowed to be less than 20° from perpendicular.

3. Connect pump inlet sub-assembly (item 1) into the inlet port. Tighten assembly as shown in figure 2.

4. Install piece of SSP-5020 tubing (item 3) between the two sub-assemblies as shown in figure 2.

5. Connect paint inlet and outlet tubes to connectors (items 1.2 and 2.3) as shown in figure 1.

WARNINGA positive displacement pump MUST have a means “to prevent the discharge pressure from exceeding the safe operating pressure of the system”.

See NFPA-33 and OSHA Standards

1.1

1.3

1.2

1.4

1.2

2.3

2.6

2.22.1

2.4

2.5

2.3

3

FIGURE 1:

A12577-00 PRESSURE RELIEF KIT

FIGURE 2:

A12577-00 INSTALLED ONTO 74644 PUMP

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General Operation

1. Flush the pump and feed lines with a suitable solvent every day of use

1. Keep solvent in the lines during long periods of down time (overnight and weekends)

2. Use 1/4 inch (6.4mm) ID input hose for normal applications. Use larger hose where highly viscous coatings material is used.

3. With siphon fed pumps:

a. Keep the coating material supply output port at the same or higher elevations as

the pump.

b. Use a supply hose that is not more than 10 feet ( 3 meters) long.

c. If the operating conditions cannot be met for a siphon fed pump, you must use a pressure supply system.

5. With pressure fed pumps, the recommended maximum inlet pressure is 60 psi ( 4.2 bar), at the pump inlet.

CAUTIONHigher inlet pressures may damage the pump seals.

NOTEIn a pressure fed system, the pump will bypass slightly, depending on the input pressure and fluid vis-cosity, thereby increasing the volume flow rate. To minimize fluid bypass, adjust the inlet pressure so it is within 5 psi of the pump output pressure.

NOTEThe rate of wear of any pump will depend on the nature of the coating material, the amount of use, and the speed of operation.

Section 4: OPERATION

CAUTIONDO NOT run the pump dry or at full speed when flushing the lines as this may gall the pump.

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General Problem Cause Solution

Severe Decrease In Flow 1. Obstructed lines2. Failed pressure supply system

1. clean or replace fluid line2. Check supply pressure at the inlet of the pump.

Pulsating Flow 1. Air in coating material supply2. Air in feed lines3. Crimped supply line.

1. look for bubbles in the supply line.2. Look for bubbles in the supply line3. Look for lined

Leakage at Pump Shaft 1. Feed pressure (at pump) in excess of 60 psi (4.2 bar)

2. Work Packing’s

1. Replace pump

2. Replace pump

Pump Frozen 1. Contaminant in paint

2. Worn pump gears

1. Flush pump with solvent, install paint filter prior to pump. If flushing does not work replace pump.

2. Replace pumpFailure to self-prime (siphon feed system)

1. Coating material supply elevation below pump inlet

2. Input obstruction

3. Input hose with too large an ID4. Input hose with too small of ID5. Input hose too long6. Loose set screws on gear hub7. Worn gears8. Loose fitting(s) on suction line causing air leak.

1. Lower pump inlet

2. Flush pump and verify inlet fitting and tubing are clear of obstruction.

3. Reduce ID4. Increase ID5. Shorten hose length6. Tighten set screw7. Replace pump8. Tighten fittings


NOTEThe 74644 fluid metering pump is not field rebuildable and spare parts are not available. Pumps may be able to be factory remanufactured, talk to a Ransburg sales representative for more details.

Be sure to flush all material from pump prior to retuning to Ransburg.

Section 5: MAINTENANCE

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PARTS LISTDESCRIPTIONPART NUMBERQTYITEM

FITTING ASSY, FLUID PUMP PRESSURE RELIEFA12572-00111/4 NPTF TEE S.S. 316A12573-0011.11/4NPTM X 1/4 NPSM ADAPTER4T-421.2HOSE CONNECTION, 1/4 NPTM X 3/8 TUBESSP-643511.3SWIVEL ADAPTER, 1/4 NPSM X 1/4 NPTM4SN-4T11.4FITTING ASSY, FLUID PUMP PRESSURE RELIEFA12576-00121/4 NPTF TEE S.S. 3164SN-4T12.11/4 NPT STREET ELBOW S.S. 316A12574-0012.21/4NPTM X 1/4 NPSM ADAPTER4T-422.3VALV, PRESSURE RELIEFA12575-0012.4HOSE CONNECTION, 1/4 NPTM X 3/8 TUBESSP-643512.53/8" OD X 1/4" ID TEFLON TUBESSP-502010"3

1.1

1.3

1.2

1.4

1.2

2.3

2.6

2.22.1

2.4

2.5

2.3

3

A12577 1/4” FLUID PUMP PRESSURE RELIEF KIT

Section 6: PARTS IDENTIFICATION

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Section 7: MANUAL CHANGE SUMMARY


Manual Changes

This manual LN-9404-00.3 was published to supercede LN-9404-00.2 Fluid Metering Pump to make the following

changes:

1. Add description of –03 and –40 pump and when to use each. (p. 9)

2. Add “factory rebuildable” and “flush all material from pump” (p. 14)

This manual LN-9404-00.1 was published to supercede LN-9404-00.0 Fluid Metering Pump to make the following chang-es:

1. Update with new part numbers

2. Remove parts breakdown of old style pumps.

3. Add alignment procedure for DC Drive pump and DDP pump.

4. Update pressure relief valve kit with new par numbers.

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WARRANTY POLICIES

LIMITED WARRANTY

Ransburg will replace of repair without charge any part/or equipment that fails 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 written safety and operating instructions, and has been used under normal operating conditions. Normal wear items are excluded.

THE USE OF OTHER THAN RANSBURG APPROVED PARTS VOIDS ALL WARRANTIES.

SPARE PARTS: One hundred and eighty (180) days from date of purchase, except for rebuilt parts (any part number ending in “R”) for which the warranty period is ninety (90) days.

EQUIPMENT: When purchased as a complete unit, (i.e. guns, power supplies, control units, etc.), is one (1) year from date of purchase.

WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY.

RANSBURG’S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BE-CAUSE OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. RANSBURG ASSUMES NO LIABIL-ITY 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:

If, in Ransburg’s opinion the warranty item in question, or other items damaged by this part was improperly installed, operated or maintained, Ransburg will assume NO responsibility for repair or replacement of the item or items. The pur-chaser, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.

Section 8: APPENDIX

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NOTES

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Product 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

320 Phillips Ave.

Toledo, Ohio 43612-1493

Telephone (toll free): 800-233-3366

Telephone: 419-470-2021

Fax: 419-470-2040

Technical Support Representatives can direct you to the appropriate telephone number for ordering spare parts.

© 2013 Ransburg. All rights reserved.

Models and specifications subject to change without notice.

Form No. AA-09-01

Litho in U.S.A.

04/13

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