LN-9272-12.0 Ransburg - Carlisle Fluid Technologies · SERVICE MANUAL LN-9272-12.0 AUGUST - 2013...

SERVICE MANUALLN-9272-12.0AUGUST - 2013

Ransburg

Ground Monitoring System For Both Metallic and Plastic Parts

GMS2

MODEL: A13170-XXXX

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS, starting on page 1, and all instructions in this manual. Keep this Service Manual for future reference.

Service Manual Price: $50.00 (U.S.)

SUITABLE SOLVENTS FOR CLEANING GMS PROBE .......................................................23TROUBLESHOOTING ...........................................................................................................24-25CONTROL UNIT ELECTRICAL SCHEMATIC ........................................................................26GMS CONTROL UNIT PARTS LIST ......................................................................................27GMS PROBE PARTS LIST.....................................................................................................28FRONT PANEL LOCKOUT ....................................................................................................29

SAFETY: 1-5SAFETY PRECAUTIONS ......................................................................................................1HAZARDS / SAFEGUARDS ..................................................................................................2-5

PAGE

INTRODUCTION: 6-10

CONTENTS

GENERAL DESCRIPTION ....................................................................................................6PRODUCT CONFIGURATION ..............................................................................................7INPUTS .................................................................................................................................8OUTPUTS .............................................................................................................................8OTHER CONSIDERATIONS ..................................................................................................8THERORY OF OPERATION ..................................................................................................8FEATURES AND BENEFITS ..................................................................................................8-9SPECIFICATIONS ..................................................................................................................9SELECTION GUIDE ...............................................................................................................10

INSTALLATION: 11-15MOUNTING THE CONTROL UNIT .......................................................................................11I/O CONNECTIONS ...............................................................................................................11PLC INTERFACE ...................................................................................................................12AC INPUT CONNECTIONS ...................................................................................................13INTERLOCKS.........................................................................................................................14RELAY CONTACT OUTPUTS ................................................................................................15LOW VOLTAGE CABLE .........................................................................................................15

OPERATION: 16-22POWERING UP CONTROL UNIT .........................................................................................16LOCKOUTS ............................................................................................................................16SET-UP ...................................................................................................................................17CALIBRATION ........................................................................................................................18SETTING THE ARC DETECT BOARD ..................................................................................19OPERATION SEQUENCE EXAMPLE ...................................................................................20-22

MAINTENANCE: 23-29

WARRANTY POLICIES: 30

LIMITED WARRANTY ...........................................................................................................30

GMS2 - ContentsRansburg

LN-9272-12.0

W A R N I N G!

W A R N I N G!

SAFETYSAFETY PRECAUTIONSBefore operating, maintaining or servicing any Ransburg electrostatic coating system, read and understand all of the technical and safety liter-ature 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 EQUIPMENT PROBLEMS. To help you recognize this informa-tion, 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 specifications and service procedures, some minor deviations may be found between this literature and your equipment. Differences in local codes and plant requirements, material delivery requirements, etc., make such variations inevitable. Compare this manual with your system installation 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 efficient operation, 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 identified.

� 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 fire codes and ordinances as well as NFPA-33 SAFE-TY STANDARD, LATEST EDITION, prior to installing, operating, and/or servicing this equipment.

GMS2 - Safety Ransburg

LN-9272-12.01

Spray Area

AREATells where hazards may occur.

HAZARDTells what the hazard is.

SAFEGUARDSTells how to avoid the hazard.

Fire Hazard

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

Protection against inadver-tent arcing that is capable of causing fire 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, 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 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 flam-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 unautho-rized equipment modifications may cause fire or injury.

If used, the key switch bypass is intended for use only during setup operations. Production should never be done with safety interlocks dis-abled.

Never use equipment intended for use in water-borne installations to spray solvent based ma-terials.

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.

GMS2 - SafetyRansburg

LN-9272-12.0 2




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 oper-ation and maintenance proce-dures will cause a fire hazard.

Protection against inadvertent arcing that is capable of caus-ing fire 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 specifically 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 flammable 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 fire 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 flushing, 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 fire 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, fire protec-tion, operation maintenance, and housekeep-ing. Reference OSHA, NFPA-33, EN Norms and your insurance company requirements.


LN-9272-12.03




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 materials and cause a fire or explosion.

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 ground-ed. 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 flooring must be provided in the spray area.

Always turn off the power supply prior to flush-ing, cleaning, or working on spray system equip-ment.

Unless specifically 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.

GMS2 - SafetyRansburg

LN-9272-12.0 4

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.




Electrical Equipment

Electrical Discharge

High voltage equipment is uti-lized in the process. Arcing in the vicinity of flammable or combustible materials may oc-cur. Personnel are exposed to high voltage during operation and maintenance.

Protection against inadvertent arcing that may cause a fire 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 fire or explosion.

Unless specifically 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 flammable 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,-Trichlo-roethane are not chemically compatible with the aluminum that might be used in many sys-tem 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 appli-cation equipment - such as material pumps, regulators, triggering 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 compatible, contact your coating supplier. Any other type of solvent may be used with aluminum equipment.

Spray Area


LN-9272-12.05

INTRODUCTION

GENERAL DESCRIPTIONThe Ransburg Ground Monitoring System (GMS) monitors the ground condition of both metallic and non-metallic parts and provides feedback, increasing the margin of safety. After scanning the part with an electrostatic charge, the GMS’scontrol unit circuitry monitors several variables and compares the reading against a pre-deter-mined standard. If the reading falls outside of an acceptable range, the notification alarm will activate, allowing adjustments or corrections to bemade, eliminating rework while increasing quali-ty. The unit can also detect and notify of any arc from an ungrounded target to ground. Improper grounding can cause overspray, excess paint build-up, thin film build, ruined parts or a safetyhazard. Both NFPA and EN (European) standards require that all metallic components inside the hazardous are be no more than one Meg Ohm from ground potential. This device insures the parts entering the hazardous location are indeedproperly grounded.

The GMS consists of:• Control Unit• Probe Detector and Sensing Unit• Cable• Machine Mount Bracket

The device must be located outside the hazardous area. It is NOT approved for use class 1 div 1 or zone 0 or 1 applications.

The control unit consists of an electrostatic gen-erator, input-output signal circuitry, and is micro-processor/software based.

The probe detector contains a high voltage cas-cade, electrode assembly and an electrical circuit capable of providing feedback to the control unit.

Probe Detector and Sensing Unit

Control Unit

GMS2 - IntroductionRansburg

LN-9272-12.0 6

------------

78983-0079131-0079107-00

A10847-00A10848-00A10849-00A12036-00A10851-00

----

“B” Dash # Description

OPTION “BB” DESIGNATIONS - MOUNTING TYPE

000102030405060708091011

Part Required

----A12552-00A12553-00A12553-00A12553-00A12553-00A12553-00A12553-00A12553-00A12553-00A12553-00A12554-00

(2) -79338-10(2) -79338-15(4) -79338-10

“A” Dash # Description

OPTION “A” DESIGNATIONS - CABLE LENGTH

123

Cables Required

10 METER15 METER20 METER

A13171-01A13171-02A13171-03

“C” Dash # Description

OPTION “C” DESIGNATIONS - PLUG STYLE

123

“C”

110/220 DOMESTIC PLUG STYLE220/240 DOMESTIC PLUG STYLE220/240 CHINA PLUG STYLE

Part Required

NO MOUNTING BRACKETFANUC PAINT MATEHOLLOW WRIST-NO ADAPTERFANUC P-145/P-155FANUC P-200/P-250ABB5400, 5002KAWASAKI KE610LMOTOMAN PX2850MOTOMAN PX2900ABB 5400 ENHANCED WRISTB&M LZ2000STATIONARY OR POLE MOUNT

“A” DESIGNATIONS

“A” DESIGNATIONS

“B” DESIGNATIONS“C” DESIGNATIONS

Base Model - Optional Designation (Ordering information only)

PRODUCT CONFIGURATIONGROUND MONITOR METAL/PLASTIC SYSTEM

A13170 - ABBC

GMS2 - Introduction Ransburg

LN-9272-12.07

INPUTS• 110 or 220VAC Main power input

• The control unit requires an input trigger signal for part detection. A limit switch, photo-eye, PLC or robot trigger signal input is acceptable.

• The device will require field calibration to the specific application.

OUTPUTS• The control unit will provide a visual signal to

alert the end user of the detection of an un-grounded part or part that causes a discharge arc to ground.

• Two contact closures (FAULTS & HV ON) are provided to signal the application of HV and the detection of an ungrounded part.

• These contacts may be hooked to a PLC, horn, or light (shown in the PLC INTERFACE section of this manual).

OTHER CONSIDERATIONS• Designed for use on metallic or non-metallic

substrates.

• Accuracy of the system is dependent on part to probe detector distance staying consistent.

• The probe to part distance should be set to 4” (10.1 cm) and should not vary more than ± 1” (2.54 cm).

• Probe detector and sensing unit must stay clean.

• Inspect the probe detector electrode every two weeks.

• Frequently check the arc detect sensing circuitry.

THEORY OF OPERATION• The part(s) to be detected are subjected to a

high voltage electrostatic charge.

• The control unit circuitry measures the amount of energy required to charge the part during the charging time selected, and compares that value with an installation specific pre-set “window”. The unit will also sense arcs between an isolated part and ground. Detection of an arc signifies a part is not properly grounded.

• If the reading falls within the end user deter-mined pre-set setpoint, the target passes the ground test.

• If there are no arcs detected between the target and ground, the arc detect portion of the test is satisfied.

FEATURES AND BENEFITS• Complete Monitoring System...consists of a

control unit, ground probe with sensing unit, mounting bracket and low voltage cables.

• Meets Stringent Safety Requirements...FM approved for use in Class I, Division II painting environments.

• Utilizes Various Input Signals for Part Detection...limit switch, photo-eye, PLC, robot signal or any 0 Volt ground trigger detection process.

• Advanced Technology...allows user to adjust control unit for specific field calibration.


LN-9272-12.0 8

SPECIFICATIONSEnvironmental / PhysicalOperations:

Control Units:

Probe:

Probe distance from substrate for accurate monitoring: 4 inches +/- one inch (100 mm +/- 25 mm)

Minimum time for measurement and result output signal: 3.5 seconds

Low voltage cable length: 10 meters standard (33’)15, meters optional

Input voltage: 110/220 VAC

Probe output: 85 kV maximum

Current output: 100 μA maximum

Height: 5.5 inches (14.0 cm)

Width: 8.5 inches (21.6 cm)

Depth: 7.5 inches (19.1 cm)

Weight: 7.5 lbs. (3.4 kg)

Length: 12.1 inches (30.7 cm)

Weight: 1 lb 14 oz (.85 kg)

Mounting bracket weight: 1 lb 3 oz (.65 kg)

Mounting bracket adjustment angles: 0, 30, 60 & 90°

FEATURES AND BENEFITS (Cont.)• User-Friendly Control Unit Software...allows

end user to control start timer, scan duration timer and alarm outputs.

• Easy to Read Visual Indicators...users receive simple, precise feedback regarding ground path strength.

• Versatile Model...compatible with electrostat-ic systems, plastic, metallic and non-metallic surfaces.

• Versatile Ungrounded Part Alert Notification...unit provides two contact closures that may be interfaced to a PLC, horn or light for ungrounded part alert. Contact closures included are:

1. One FAULT indicator (Any fault condition detected)2. One HIGH VOLTAGE ON indicator

GMS2 - Introduction Ransburg

LN-9272-12.09

SELECTION GUIDEA13170 - ABBC

TABLE A : LOW VOLTAGE CABLE LENGTH

1 = 10 meter2 = 15 meter3 = 20 meter

TABLE BB : MOUNTING CONFIGURATION00 = no mounting adapter01 = Fanuc Paint Mate02 = hollow wrist robot (no adapter)03 = Fanuc P-145 / P-15504 = Fanuc P-200 / P-25005 = ABB 5400 / 500206 = Kawasaki KE610L07 = Motoman PX285008 = Motoman PX290009 = ABB 5400 enhanced wrist10 = B&M LZ200011 = stationary or pole mount

TABLE C : PLUG STYLESELECTION1 = 110/120 VAC, 50/60 Hz USA2 = 220/240 VAC, 50/60 Hz European3 = 220/240 VAC, 50/60 Hz China

GMS 2 Part Number Configuration


LN-9272-12.0 10

INSTALLATIONInstallation Prints:Drawings and information contained in this section and the appendix of the manual are applicable to most installations. However in some special cases, Ransburg may supply custom installation drawings for your specific site. It is highly recommended that if your installation differs significantly from the installation drawings supplied by Ransburg, you notify your Ransburg representative to ensure that standard installation practices are not violat-ed and to have your prints updated to reflect the installation accurately for future reference.

Equipment Locations:The GMS control panel must be located outside of the hazardous area. If in doubt, contact your Ransburg representative for clarification.

MOUNTING THE CONTROL UNITThe GMS control panel has an optional mounting kit available 79527-00. This kit allows either top mounting or back mounting, with either swing-away or fixed attachment. There are four convenient

ways of mounting the enclosure assembly using the included hardware. See the Appendix section for the different mounting configurations available.

I/O CONNECTIONSFor maximum noise immunity, I/O wiring should be run in conduit or cables having a foil shield with an overall braided shield. The foil shield provides 100% shielding, while the braid provides a means of making proper 360° shield terminations at the cable to cabinet connection points. To make I/O connections using shielded cable, perform the following:

1. Remove the cable grommet hardware from the I/O connector housing.

2. Route the desired length of I/O cable through the connector housing and mark 1” span of cable that passes through connector housing to be stripped to braid.

3. Remove cable and strip marked 1” section to cable braid.

4. Slide the cable grommet hardware onto the cable.

5. Route the cable back through the connector housing and connect its wires to the desired I/O terminals inside the GMS Control Unit or power supply.

6. Tighten the cable grommet ensuring the grommet spring makes 360° contact with the exposed braid of the cable, for maximum noise immunity.

7. For maximum noise immunity, connect the braid of the cable to earth ground at the end opposite the control unit or power supply.

W A R N I N G! � The GMS 2 system must be located out-

side of the hazardous area.

� When mounting the control unit to a wall or ceiling, the 79527-00 Mounting Kit should be used. If mounting to a non-metallic wall or ceil-ing, the mounting screws must be secured to the wall or ceiling studs. If mounting to a met-al wall or ceiling (such as a spray booth) the wall or ceiling must be at least 0.050” (1.2mm) thick. In both cases, the customer must supply the screws to attach the brackets to the wall or ceiling. These screws should be at least 1/4” (6mm) in diameter.

C A U T I O N!

GMS2 - Installation Ransburg

LN-9272-12.011

PLC INTERFACEThe PLC interface for the Ground Monitor is very simple (Figure 1).

1. There is an input (2TB-5) to tell the process to initialize. This sinking input circuit needs a ground supplied to initialize the process.

2. The fault output is based on a non-grounded part detection. If a non-grounded part is detected a relay will close a set of dry contacts (2TB-1 to 2TB-2) signaling a device of the users choice (light, horn, PLC, etc).

Figure 1

3. A “High Voltage On” output is also available to signal an external device (light, horn, PLC, etc). A set of dry contacts (2TB-3 to 2TB-2) close when the high voltage is On. See page 20 for the maximum allowable electrical ratings for the relay contacts.

GMS2 - InstallationRansburg

LN-9272-12.0 12

AC INPUT CONNECTIONS

For non-conduit installations, plug the detachable AC line cord into the receptacle on the rear of the control unit. Plug the other end of the line cord into a properly grounded 120 volt AC outlet.

For installations where it is required to run the AC input wiring in conduit, perform the following.

1.Ensure the AC line cord is unplugged and remove the AC inlet receptacle wiring from TB1-N, TB1-L1, TB1-EARTH GROUND (see figure 2)

2. Remove the mounting hardware from the AC inlet receptacle and remove it from the rear of the control unit.

3. Install the conduit adapter plate (supplied) in the hole where the AC inlet receptacle was removed. (see Figure 2)

4. Install the AC input wiring (0.8mm2 (18 AWG) minimum) through the conduit adapter plate using conduit and wire to TB1 as follows.

Figure 2

� When using conduit to route the AC input wiring to the control unit, the last several feet of conduit attached to the control unit should be of a flexible type, such that the control unit chassis can be slid out of its enclosure for testing and set-up purposes.

NOTE

Hot/Line to TB1-L1Neutral/Common to TB1-NGround to TB1-EARTH GROUND


LN-9272-12.013

INTERLOCKS

Interlocks required by code are as follows:

• Booth Fan Interlock - When the booth fan is on, a contact closure is made.

• Conveyor Interlock - when the conveyor is moving a contact closure is made.

� Some codes may require the interlock wiring to be run in conduit. In this case shielded cable is not necessary, but the conductors used should still meet the rat-ings specified above. The interlock con-tacts (supplied by user) should be rated for at least 1-amp at 240 volts AC.

NOTE

W A R N I N G! � Failure to connect interlocks could result

in fire or explosion.

W A R N I N G! � ALWAYS ensure that high voltage is OFF

before cleaning the ground monitor compo-nents with solvent. NEVER clean the ground monitor components with high voltage ON, as this is a severe fire hazard and risk to per-sonnel safety.

Figure 3

To install the control unit interlocks perform the following:

1. Turn the control unit off and remove the fuses.

2. Loosen the front panel screws and slide the control unit chassis out.

3. Using a small blade screwdriver, remove the factory installed test jumper from TB1-L2 to TB1-L3 (Figure 3).

4. Using a shielded cable for the interlock wiring (supplied by user), route through the interlock connector on the rear of the control unit and ter-minate to TB1-L2 and TB1-L3. The shielded cable must have a minimum rating of 300V and 105°C and its conductors should be 0.8mm2 (18 AWG) minimum. Secure the cable to the interlock con-nector so that the shield of the cable is connected to the chassis of the enclosure.

5. Slide the chassis back in, secure the front panel screws, and replace the fuses.

GMS2 - InstallationRansburg

LN-9272-12.0 14

RELAY CONTACT OUTPUTSA set of relay contacts for high voltage (CR1) and fault (CR2) conditions is provided at TB2-3 and TB2-1 (Figure 4). One end of these relay contacts are connected together and also connected to a source input terminal at TB2-2 (Figure 4). When a source voltage is present at TB2-2 and either the high voltage is on or a fault condition occurs, the source voltage will become available at the output end of the corresponding contact. Maximum contact ratings are as follows:

C A U T I O N!

When wiring to TB2, use a shielded cable and route the wiring through the standard I/O connector.

An internal 24VDC source voltage is available at TB2-4. Using a jumper wire, this voltage may be connected to TB2-2 to be used as the source voltage for the relay contact outputs. In this case, the total current sourced should not exceed 1- amp (Figure 3).

LOW VOLTAGE CABLEConnect the low voltage cable from the control unit to the applicator using a wrench to tighten.

With the GMS design, multiple cables may be connected together to create the length required, up to a maximum of 20m (66 ft.). To connect the cables, insert the male end of one cable into the female end of the other. Tighten both cable con-nectors against each other using two (2) 16mm (5/8”) open-end wrenches.

� DO NOT over tighten the low voltage connection at the applicator. The plastic parts could be damaged.

Description DC

MAX SWITCHING CAPACITY 60 W MAX OPERATING CAPACITY 30 VDCMAX OPERATING CURRENT 2A

MAXIMUM CONTACT RATINGS (RESISTIVE LOADS)


LN-9272-12.015

OPERATION

POWERING UP CONTROL UNITWhen the AC power is turned on, the unit will display the set point number on the SEC display and the software revision level in the STATUS display for 2-3 seconds.

LOCKOUTSThere are lockouts that may be done at the PC board (see Appendix section). These lockouts may be used individually or in combination as required. If the jumpers are disconnected, the original functions are re-enabled. After changing any jumpers, the AC power must be cycled for the new setting to take effect.

Front Panel LockoutThis feature locks out any changes to the timers from the front panel of the control unit. Default from the factory the front panel lock out is disabled.

1. Set the timers to the desired values using the front panel buttons. This must be set prior to in-stalling the jumper.

2. Turn AC power off and access the interior of the control unit.

3. Place the jumper across the two (2) pins at location 16 on the main PC board (see Appendix section).

4. Close the control unit and turn AC power back on. Pressing the front panel +, -, or setpoint buttons will now have no effect on the timers.

SOFTWARE REVISIONSETPOINT

ON-OFF SWITCH

GMS2 - OperationRansburg

LN-9272-12.0 16

SET-UPThere are 3 timers to set before operating the Ground Monitor:

1. WAIT TIMER: The first timer is the wait time. This will be the time to wait before turning on High Voltage after a signal to start the process has been received. (default: 3 sec)

2. DATA TIMER: The second timer sets how long the sample will be. This is High Voltage on time. The minimum settable time is 2 seconds, the average time necessary to get a good reading is 3.5 seconds. (default: 5 sec)

DecreaseTime

Increase Time HV LED Status

Display LED BAR

Power Switch

Reset Button

Control Button

Display Timer

Data Timer

Wait Timer

3. DISPLAY TIMER: The third timer sets the amount of time the result is shown for. Note: if another part input is received during this count-down, the entire process will start over at step 1. (default: 5 sec)

� The data timer must be set to the time the target is in front of the unit. If high volt-age is on and the target is not in front of the unit, an error will occur.

NOTE

GMS2 - Operation Ransburg

LN-9272-12.017

CALIBRATION1. Place the part to be checked in front of the Ground Monitor probe

2. Assure target distance is 4” (±1”)

3. Use a megger set to 1 KiloVolt (KV) output to verify a good earth ground is present on part. The NFPA /EN standards define ground as 1 Meg Ohm or less resistance value.

4. Press the “Control” button on the controller. The entire LED bar (green yellow, and red) under status display will light up to indicate the unit is in calibration mode.

5. Press the red “Override” button located on the back of the controller (you may need to hold the button in for a second). This button manually begins a cycle.

6. When the high voltage comes on allow the num-bers under “Status” to settle and then press the “Control” and “Reset” buttons at the same time to store the calibration value. The value will typically be in the rang of 60 – 80. The default value is 55.

7. When the calibration value is accepted the LED light bar will turn off.

Special Keys:

1 and Reset - Pressing these keys together will display the saved set point in the status window. The value will display for 5 seconds, and then go back to regular mode2 and Reset - Pressing these keys together will display the cumulative amount of hours the HV has been on.

3 and Reset - Will reset the set point and timers to factory default values. The unit must be turned off and back on for the default values to take effect.

Defaults:Timer 1 = 3.0 secondsTimer 2 = 5.0 secondsTimer 3 = 3.0 secondsSetpoint = 55

Front of Controller LED Bar

Control Button Reset Button

Back of Controller

Override Button


LN-9272-12.0 18

SETTING THE ARC DETECT BOARD1. The arc detect system is set at the factory and should be function for most applications. However if a known ungrounded target that arcs does not create and “ACD” in the Status Window when tested then some adjustment may be necessary.

1 Potentiometer Adjustment Screw2 Arc Detect Board3 Main PC Board

W A R N I N G!Any testing that creates arcs between the targetand ground must be done outside the haz-ardous area.

� The best way to test for this is to iso-late the part from ground (hanger, carrier or other conveyor device) is by applying masking tape between the target and ground. This test should be performed in the area where the unit will be perma-nently located.

NOTE

2. Open the (4) screws on the front panel and carefully pull the drawer out of the case.

3. The arc detect board is located near the main pc board as shown in the figure below.

4. Rotate the potentiometer screw counter-clock-wise until a click is detected. This is minimum adjustment position.

5. With the probe at the proper distance away from the isolated target, press the override button on the back of the unit.

6. If the term “ACD” appears in the status win-dow, turn the potentiometer 1 turn in the clock-wise direction. Re-test by pressing the override button. Continue this method until the “ACD” is not displayed in the “Status Window”. Once this isobserved, adjust the potentiometer 1/2 turn in the counter-clockwise direction.

7. Re-test by pressing the override button and “ACD” should be displayed. If not adjust an addi-tional 1/2 turn counterclockwise till the “ACD” is not displayed in the status window.

8. Verify the set up by properly ground the target and monitoring the “Status Window” . The level of grounding will be displayed, 5 being the best, 1 needing attention to ground soon.

DescriptionItem


LN-9272-12.019

OPERATION SEQUENCE EXAMPLE

1. Part or part hanger trips limit switch • The process is initialized • In process lights illuminated

2. Wait timer (Timer #1) counts down

Low Voltage& Signal Cables

Limit Switch


Limit Switch

Conveyor

Conveyor


LN-9272-12.0 20

OPERATION SEQUENCE EXAMPLE (Cont.)


Limit Switch

3. When wait timer expires high voltage is energized

4. High voltage will stay on for the length of the Timer #2

5. When HV on timer expires, high voltage is turned off and an indi-cator light is displayed • Red = not grounded • Orange/Yellow = borderline • Green = OK • ACd = arc detected (not grounded)


Limit Switch

Conveyor

Conveyor


LN-9272-12.021

OPERATION SEQUENCE EXAMPLE (Cont.)

6. The indicator light will retain lit until timer #3 times out or another input is received from limit switch.

• If the part is detected to be ungrounded, the FAULT light will illuminate in addition to the red light.• The relay contact will also close to signal an external device (light, horn PLC, etc)


Limit Switch


Limit Switch

Conveyor

Conveyor


LN-9272-12.0 22

MAINTENANCE

SUITABLE SOLVENTS FOR CLEANING GMS PROBE

When cleaning the probe, a suitable solvent for cleaning depends on the part(s) of the applicator to be cleaned and the material that needs to be removed. Ransburg recommends that all exterior cleaning be done with non-polar solvents to prevent a conductive residue on critical components. We also understand that some of these solvents do not always meet the cleaning needs of some materi-als. If conductive polar solvents are used to clean the applicator components, all residues must be removed using a non-conductive non-polar solvent (i.e. high flash Naphtha). If there are any questions as to what solvents are best for cleaning, contact your local Ransburg distributor and/or your paint supplier. The GMS probe and low voltage cable assemblies should not be submerged or soaked in solvent. However, the outer surfaces of these items can be wiped with a suitable cleaning sol-vent. All electrical components cannot be cleaned or soaked in any solvents.

W A R N I N G! � The user MUST read and be familiar with

the safety instructions in this manual.

� If compressed air is used in cleaning, REMEMBER that high pressure air can be dangerous and should NEVER be used against the body. It can blind, deafen, and may even penetrate the skin. If used for cleaning equipment, the user should wear safety glasses.

� ALWAYS turn the control unit’s power off prior to cleaning and servicing the equip-ment.

� Be SURE the power is OFF and the system is grounded before using solvent to clean ANY equipment.

� DO NOT operate a faulty applicator!

� Use of ungrounded or plastic containers may cause fire or explosion.

� Cleaning of the exterior surface of the applicator should be done with non-polar solvents. If cleaning requires the use of po-lar solvents, the applicator should be wiped down with non-polar solvent prior to going back into use. Using polar solvents will leave a semi-conductive film on the surface of the applicator that will effect efficiency of the applicator and cause damage to the compo-nents.

GMS2 - Maintenance Ransburg

LN-9272-12.023

Overload Fault (OL)This fault will occur if the current output reaches 90uA. Remove the condition causing excess microamps and reset the fault. Typically the target distance from the probe to the part is too close. Back up target distance and re-calibrate.

TROUBLESHOOTING

FAULT DESCRIPTIONSWhen a fault occurs, the Fault Indicator on the front of the control unit will light, a fault code will be displayed on the status meter. Faults can be reset by pressing the Reset button on the front of the control unit .

Safety Fault (SF)If this fault occurs, the fault indicator at the control unit will illuminate, a SF indication will show in the status display. This fault will occur if the micropro-cessor detects the unit is trying to output voltage to the applicator with no trigger. If this occurs, reset the fault from the control unit. If this fault occurs repeatedly upon reset, replace the main PC board. Other causes of this fault include a broken ground path between the applicator and control unit caused by a faulty cable or plug assembly.

Over Voltage Fault (OU)This fault will occur if the microprocessor detects the unit is trying to output voltage above that required for the application. If this occurs, reset the control unit. If this fault continues to occur, replace the main PC board.

Cable Fault (CF)This fault will occur if high voltage is active and the microprocessor detects that no current is being supplied to the applicator. Typical causes include a broken or improperly connected low voltage cable. Other causes could include loose wiring in the control unit or a faulty cascade circuit in the applicator. When this fault occurs, determine the cause of the problem, then press the reset button.

GMS2 - MaintenanceRansburg

LN-9272-12.0 24

Low Current Set point Fault (LC)This fault will occur if the set point is set below a factory preset threshold. This is to prevent unacceptable calibration values. If this occurs use an insu-lation test meter with at least 1KV output (Megger), to check that the target is properly grounded, and verify the target distance is 4 inches, then re-calibrate the unit. To recover from a LC fault the calibration must be set very quickly, then go back and allow the voltage to settle and reset the set point again.

FAULT DESCRIPTIONS (continued)

Current Limit Fault (CL)This fault will occur if the output current exceeds the maximum current by more than 20 uA for 2-3 seconds. If this occurs, reset the fault from the applicator or control unit. If this fault occurs repeatedly, investigate the main PC board or applicator barrel for the cause.

Voltage Feedback Fault (UF)This fault will occur if the microprocessor detects a loss of the voltage feedback signal. If this occurs, reset the fault from the control unit. If this fault occurs repeatedly, replace the main PC board.

Feedback Fault (FF)This fault will occur if the microprocessor detects a loss of the current feed-back signal from the applicator. If this occurs, reset the fault from the control unit. If this fault occurs repeatedly, investigate the main PC board, cable, plug assembly, or cascade for the cause.

Arc Detection Fault (ACd)This fault will occur if the microprocessor detects an arc between ground and the target.


LN-9272-12.025

CONTROL UNIT ELECTRICAL SCHEMATIC


LN-9272-12.0 26

Item No. Part Number

GMS CONTROL UNIT PARTS LIST

DescriptionQTY.

GMS CONTROL UNIT PARTS LIST

1 1 80116-01 ASS’Y. PC BOARD GMS-2 2 1 A13183-00 ASS’Y. ARC DETECT BOARD 3 2 72771-06 FUSE

12

3


LN-9272-12.027

1 1 A12516-00 GROUND MONITOR BODY 2 1 A13175-00 ASS’Y., PICKUP MOUNT 3 1 79736-00 ASS’Y, BARREL, SOLO 85 MACHINED 4 4 LSFA0026-00 SCREW, FIBERGLASS 5 1 A12513 FLUID PASSAGE PLUG 6 1 A12517-00 ASS’Y., PLUG , LV 7 3 79798-04 SHCS M5X0.8 X 40 LG 8 1 79832-201 GASKET, BARREL 9 1 79809-00 PRESSURE REDUCER, ATOM AIR SOLO 10 1 79542 AIR CAP SWIRL NOZZLE 11 1 79724 NUT, RETAINING 12 1 79544-00 FLUID NOZZLE, SWIRL AIR 13 1 A12540-00 SET SCREW 14 1 A12519 NEEDLE SHROUD 15 1 79600-01 ASS’Y. CASCADE GMS 16 1 79853-01 ASS’Y., NEEDLE SHAFT, SOLO 17 1 79854-00 ASS’Y. WRENCH SOLO (NOT SHOWN) 18 1 A13187-00 LABEL, GM2 NOT 1 LSCH0009-00 DI-ELECTRIC GREASE SHOWN

Item No. Part Number

GMS PROBE PARTS LIST

DescriptionQTY.

2

4

7618

113

1614

15

59

3

12 10

11

8

GMS PROBE PARTS LIST


LN-9272-12.0 28

FRONT PANEL LOCKOUT

JUMPER 16INSTALLEDFRONT PANELCONTROLDE-ACTIVATED


LN-9272-12.029

WARRANTY POLICIES

LIMITED WARRANTY

Ransburg will replace or repair without charge any part and/or equipment that falls within the specified time (see below) because of faulty workmanship or material, provided that the equipment has been used and maintained in accordance with Rans-burg’s written safety and operating instructions, and has been used under normal operating con-ditions. Normal wear items are excluded.

THE USE OF OTHER THAN RANSBURG AP-PROVED PARTS, VOID ALL WARRANTIES.

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

EQUIPMENT: When purchased as a complete unit, (i.e., guns, power supplies, control units, etc.), is one (1) year from date of purchase. WRAPPING THE APPLICATOR IN PLASTIC, SHRINK-WRAP, ETC., WILL VOID THIS WARRANTY.RANSBURG’S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS. THERE ARE NO IMPLIED WARRANTIES NOR WARRANTIES OF EITHER MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. RANSBURG

ASSUMES NO LIABILITY FOR INJURY, DAM-AGE TO PROPERTY OR FOR CONSEQUEN-TIAL 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 purchas-er, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable.

GMS2 - Warranty PoliciesRansburg

LN-9272-12.0 30

Form No. LN-9272-12.0Litho in U.S.A.8/13

Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts.

Manufacturing1910 North Wayne Street Angola, Indiana 46703-9100Telephone: 260-665-8800 Fax: 260-665-8516

Technical Service — Assistance320 Philips Ave.Toledo, Ohio 43612-1493Telephone (toll free): 800-233-3366Fax: 419-470-2233

© 2013 Ransburg. All rights reserved.Models and specifications subject to change without notice.

Ransburg

LN-9272-12.0 Ransburg - Carlisle Fluid Technologies · SERVICE MANUAL LN-9272-12.0 AUGUST - 2013...

Documents

Transcript of LN-9272-12.0 Ransburg - Carlisle Fluid Technologies · SERVICE MANUAL LN-9272-12.0 AUGUST - 2013...