FIBEROPTIC FLOWMETER HIGH AND LOW PRESSURE

Transcription

1 SERVICE MANUAL FM FEBRUARY FIBEROPTIC FLOWMETER HIGH AND LOW PRESSURE MODEL: A 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.)

2 Fiberoptic Flowmeter - Contents CONTENTS PAGE SAFETY: 1-5 SAFETY PRECAUTIONS...1 HAZARDS / SAFEGUARDS SPECIFICATIONS: 6-7 SPECIFICATIONS INTRODUCTION: 8-10 THEORY OF OPERATION...8 TRANSMITTER...8 RECEIVER...9 FIBEROPTIC CABLING...9 HANDLING AND STORAGE PRECAUTIONS...10 FLOW RATE ACCURACY...10 FLUID PASSAGES...10 MOUNTING LOCATION FOR THE TRANSMITTER...10 INSTALLATION: INSTALLATION LOCATIONS FOR TRANSMITTER AND RECEIVER...12 INSTALLING THE TRANSMITTER...12 CONNECTING THE SYSTEM...13 SYSTEM VERIFICATION AND TROUBLESHOOTING...14 OPERATION: GENERAL OPERATION...15 CALIBRATION...15 FLOWMETER SERVICING...15 SERVICE MAINTENANCE: PREVENTIVE MAINTENANCE...17 CLEANING THE METER AND TRANSMITTER...17 AUTOMATIC CLEANING OF THE FLOWMETER...17 TROUBLESHOOTING GUIDE PARTS IDENTIFICATION: 21 A FIBEROPTIC FLOWMETER - PARTS LIST...21 WARRANTY POLICIES: 22 LIMITED WARRANTY...22 FM-14-03

3 Fiberoptic Flowmeter - Safety 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 EQUIPMENT PROBLEMS. To help you recognize this information, we use the following symbols. Please pay particular attention to these sections. A WARNING states information to alert you to a situation that might cause serious injury if instructions are not followed. A CAUTION states information that tells how to prevent damage to equipment or how to avoid a situation that might cause minor injury. A NOTE is information relevant to the procedure in progress. While this manual lists standard 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 drawings and appropriate Ransburg equipment manuals to reconcile such differences. W A R N I N G 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 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 SAFETY STANDARD, LATEST EDITION, prior to installing, operating, and/or servicing this equipment. W A R N I N G The hazards shown on the following pages may occur during the normal use of this equipment. Please read the hazard chart beginning on page 2. 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. FM

4 Fiberoptic Flowmeter - Safety AREA Tells where hazards may occur. Spray Area HAZARD Tells what the hazard is. 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 or Controller shutdown indicates a problem in the system requiring correction. SAFEGUARDS Tells how to avoid the hazard. 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 maintenance. 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 solvents used for cleaning must have a flash point at minimum of 5 C (9 F) greater than the ambient temperature. It is the end users responsibility to insure this condition is met. Spray booth ventilation must be kept at the rates required by NFPA-33, OSHA, country, and local codes. In addition, ventilation must be maintained during cleaning operations using flammable or combustible solvents. Electrostatic arcing must be prevented. Safe sparking distance must be maintained between the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage is required at all times. Test only in areas free of combustible material. Testing may require high voltage to be on, but only as instructed. Non-factory replacement parts or unauthorized equipment 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 disabled. Never use equipment intended for use in waterborne installations to spray solvent based materials. 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. FM

5 Fiberoptic Flowmeter - Safety AREA Tells where hazards may occur. Spray Area HAZARD Tells what the hazard is. Explosion 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 or Controller shutdown indicates a problem in the system requiring correction. SAFEGUARDS Tells how to avoid the hazard. Electrostatic arcing must be prevented. Safe sparking distance must be maintained between the parts being coated and the applicator. A distance of 1 inch for every 10KV of output voltage is required at all times. Unless specifically approved for use in hazardous 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 combustible materials. The current overload sensitivity (if equipped) MUST be set as described in the corresponding section of the equipment manual. Protection against inadvertent arcing that is capable of causing fire or explosion is lost if the current overload sensitivity is not properly set. Frequent power supply shutdown indicates a problem in the system which requires correction. Always turn the control panel power off prior to 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 accordance with NFPA-33, EN Have fire extinguishing equipment readily available and tested periodically. General Use and Maintenance Improper operation or maintenance may create a hazard. Personnel must be properly trained in the use of this equipment. Personnel must be given training in accordance with the requirements of NFPA-33, EN Instructions and safety precautions must be read and understood prior to using this equipment. Comply with appropriate local, state, and national codes governing ventilation, fire protection, operation maintenance, and housekeeping. Reference OSHA, NFPA-33, EN Norms and your insurance company requirements. FM

6 Fiberoptic Flowmeter - Safety AREA Tells where hazards may occur. Spray Area / High Voltage Equipment HAZARD Tells what the hazard is. 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. SAFEGUARDS Tells how to avoid the hazard. Parts being sprayed and operators in the spray area must be properly grounded. Parts being sprayed must be supported on conveyors or hangers that are properly grounded. The resistance between the part and earth ground must not exceed 1 meg ohm. (Refer to NFPA-33.) Operators must be grounded. Rubber soled insulating 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 applicator 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 required 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 flushing, cleaning, or working on spray system equipment. Unless specifically approved for use in hazardous locations, all electrical equipment must be located outside Class I or II, Division 1 or 2 hazardous areas, in accordance with NFPA-33. FM

7 Fiberoptic Flowmeter - Safety AREA Tells where hazards may occur. Electrical Equipment HAZARD Tells what the hazard is. Electrical Discharge High voltage equipment is utilized in the process. Arcing in the vicinity of flammable or combustible materials may occur. 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 correction. An electrical arc can ignite coating materials and cause a fire or explosion. SAFEGUARDS Tells how to avoid the hazard. Unless specifically approved for use in hazardous locations, the power supply, control cabinet, and all other electrical equipment must be located outside Class I or II, Division 1 and 2 hazardous areas in accordance with NFPA-33 and EN 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 circuits disabled. Before turning the high voltage on, make sure no objects are within the sparking distance. 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 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. Spray Area Explosion Hazard Incompatible Materials Halogenated hydrocarbon solvents for example: methylene chloride and 1,1,1,-Trichloroethane are not chemically compatible with the aluminum that might be used in many system components. The chemical reaction caused by these solvents reacting with aluminum can become violent and lead to an equipment explosion. Aluminum is widely used in other spray application equipment - such as material pumps, regulators, triggering valves, etc. Halogenated hydrocarbon solvents must never be used with aluminum equipment during spraying, 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. FM

8 Fiberoptic Flowmeter - Specifications SPECIFICATIONS MATERIAL OF CONSTRUCTION Body: Gears: Bushings: Shafts: Seal: Filtration: Connections: Weight: 303 Stainless Steel Stainless Steel (Hardened) Tungsten Carbide Tungsten Carbide PTFE 120 Micron (Minimum) Threaded 3/8 AN (F) 4.5 lbs. (2.0 kg) Transmitter MECHANICAL Enclosure Material: Fiber Filled Nylon 6/6 Fiberoptic Cable Orientation: Perpendicular to fluid connections. Transmitter Mounting: Polarized (One way only) ENVIRONMENTAL Operating Temperature Range: -40 to F (-40 to + 50 C) Accuracy: + /- 0.5% (System dependent) Working Pressure: 5000 psi (345 Bar) 100 F ELECTRICAL Battery Life: 1.5 years minimum REGULATORY Classification: Intrinsic Safety - Class 1, Division 1, Groups C, D Approvals: FM (Factory Mutual) Class 3600 & 3610 Receiver MECHANICAL Enclosure Material: Enclosure Size: Base: Receiver: Enclosure Ingress: Protection (IP) Class Enclosure Mounting Means: ELECTRICAL Power Supply Input Voltage: Power Supply Input Current: Output Pulse Width: Output Configurations: Output Current (Source or sink): Plastic 2.3 L x 1.6 W x 1 H 1.4 L x 1.4 W x 2.2 H IP50 DIN rail clips or direct to enclosure with tapped holes Volts DC 100 ma maximum 1.0mS Isolated Output voltage sourced at supply voltage 5.0 ma maximum (Continued On Next Page) FM

9 Fiberoptic Flowmeter - Specifications System FIBEROPTIC LINK Operational Length: Fiber Connector: Fiber Cable: Fiber Cable Bend Radius: Available Cable Lengths: PULSE FREQUENCY (OUTPUT) (Flow rate on meter) Minimum: Maximum: 10 to 100 ft. Proprietary Glass fiber encased in protective tubing 6 in. Minimum 10, 15, 30, 45, 60, and 100 ft. (For other lengths please consult manufacturing facility.) 1.2 Hz (72 pulses/min or 9 cc/min*) 500 Hz (30,000 pulses/min or 3,750 cc/min*) * (Assuming a flowmeter with a calibration value of 8,000 ppl.) FM

10 Fiberoptic Flowmeter - Introduction INTRODUCTION THEORY OF OPERATION Fluid flowing through the flowmeter causes the spur gears within the meter to rotate at a speed, which is proportional to the rate of flow through the meter. The total number of gear rotations is proportional to the total amount of fluid that flowed through the meter during these gear rotations. Measurement of the gear rotation provides the information that the control system requires. TRANSMITTER The transmitter is contained in a plastic enclosure and was designed to be mounted to the top of the flowmeter. The meter and transmitter are designed to be intrinsically safe. Thus they can be mounted in hazardous (classified) locations containing potentially explosive atmospheres. The fiberoptic transmitter is located on top of the flowmeter. A sensor extends from the transmitter enclosure into the flowmeter. This sensor is positioned over the teeth of one of the rotating gears. As the gear teeth rotate past the sensor it causes the sensor to see a changing magnetic field. This changing magnetic field is converted into an electrical signal by the electronics inside the transmitter assembly. The signal from the sensor is fed into the electronics module. The electronics module first conditions the signal from the sensor and turns it into a logic level digital signal. The flow rate information is then fed to a driver circuit that drives an LED. A self-contained non-replaceable battery powers the transmitter. This battery is designed to provide power for several years of use under normal operating conditions. The signal encoding method is designed to use the minimum amount of battery power while fluid is flowing and virtually no power when fluid is not flowing. The optical pulse stream is conveyed through the fiberoptic cable to the receiver. The receiver first converts the light pulses back into electrical signals. These pulses are then fed to the output section for driving the attached control equipment. One square wave pulse is fed to the control equipment every time a gear tooth passes by the sensor in the transmitter. Figure 1: Fiberoptic Transmitter A sensor protrudes from the bottom of the transmitter enclosure. When mounted on a flowmeter this sensor senses the rotation of the gears beneath it in the flowmeter. A connector for the fiberoptic cable protrudes from the side of the enclosure. It is important that both the sensor and the fiberoptic connector be kept clean from any contaminants. FM

11 Fiberoptic Flowmeter - Introduction RECEIVER The receiver module is enclosed in a relay-style plastic enclosure with a female fiberoptic cable connection on one side. It plugs into a standard octal-style relay socket (included). It is designed to be mounted inside an industrial control cabinet. Mounting can either be done utilizing the DIN Rail clips or using two screws through the base of the socket. There is an LED protruding from the top of the enclosure that illuminates any time it is receiving pulses from the transmitter. FIBEROPTIC CABLING This fiberoptic transceiver system uses a custom designed cabling system. The cabling system consists of 2 connectors, the glass optical fiber and protective tubing. The tubing protects the internal fiber from excessively tight radius bends that would damage it. The protective outer jacket also keeps the enclosed fiber from absorbing chemical vapors that would degrade the fiber s ability to transmit light over time. The cabling is purchased and installed as a completed assembly. Field splicing or modification of cable length is not possible. Refer to Table 1 below for available cable lengths. Figure 3: Fiberoptic Cable Assembly TABLE 1 - AVAILABLE F.O. CABLE LENGTHS Figure 2: Receiver Part # Length A A A A A A FM

12 Fiberoptic Flowmeter - Introduction HANDLING AND STORAGE PRECAUTIONS C A U T I O N The transmitter contains a non-replaceable battery power source which is designed to power the unit for several years of normal operation. The transmitter functions by detecting very weak magnetic fields. Exposure to stray magnetic fields during shipping, handling, and storage can prematurely deplete the battery. Keep the transmitter at least 12 away from devices which generate stray magnetic fields. Examples of these devices are energized transformers, florescent light ballasts, TVs, computer monitors, and lineenergized wiring. C A U T I O N The fiberoptic cable assemblies contain a glass optical fiber that can be permanently damaged if bent in too small of a radius. Observe the minimum bend radius as noted in the specifications section of this manual. Keep the transmitter pickups away from rust, iron filings, and other magnetic debris which will stick to the pickups. This debris will not cause any damage to the transmitter but will need to be completely removed before the transmitter is mounted on a flow meter. Protect the fiberoptic connectors on both the transmitter and receiver from the ingress of dirt, dust and debris until the fiber cabling is attached. There are small rubber caps on both ends of the fiberoptic cable when it is shipped. Do not remove them until ready to insert them into either the flowmeter or receiver. FLOW RATE ACCURACY Flow rate accuracies of 0.5% are not uncommon with many fluids if the flowmeters are calibrated at or near the expected flow rates. Even with wide flow rate swings (such as when used with robots under analog control) accuracies of + /- 2% are achievable. FLUID PASSAGES The flowmeter uses a 3/8 AN female fitting. This style fitting eliminates flow dead space or exposed threads, and also eliminates the need for specially designed fittings or PTFE inserts. By creating a streamlined fluid passage, color change time of the meter is improved. MOUNTING LOCATION FOR THE TRANSMITTER C A U T I O N The transmitter functions by detecting changes in very weak magnetic fields caused by the rotation of the gears within the flowmeter. Unfortunately, it will also respond to stray magnetic fields if they are present from other sources. Stray fields can be caused by nearby transformers, relays, solenoids, or AC line energized wiring. For proper operation, the transmitter must be located away from these stray fields. Installing the transmitter in a location that exposes it to stray magnetic fields will result in improper operation. FM

13 Fiberoptic Flowmeter - Installation INSTALLATION Ensure proper fluid filtration is provided on the inlet side of the flowmeter. The unit may be mounted using the mounting bolt pattern shown in Figure 4. Always mount the flowmeter with the gear faces perpendicular to the horizon of the earth (i.e. - Vertical). This minimizes the effect of gravity on the gears. The direction of flow must be plumbed as marked on the side label of the meter. The fluid inlet is opposite the sensor connection. NOTE It is highly recommended that the flowmeter be plumed with the fluid inlet on the bottom and outlet at the top to minimize air entrapment in the meter. For waterborne applications the meter body should be isolated from ground. Figure 4: Views of Flowmeter Bodies FM

14 Fiberoptic Flowmeter - Installation INSTALLATION LOCATIONS FOR TRANSMITTER AND RECEIVER The fiberoptic transmitter / flow meter is designed to be intrinsically safe and may be mounted in a hazardous (classified) location which may contain a potentially explosive atmosphere. The transmitter is intrinsically safe as long as it is installed in accordance with the hazardous area classification defined in the Specification section in the Introduction section of this manual. Installing the transmitter in a hazardous area more severe than that for which it is rated poses a risk of fire, explosion, and bodily injury up to and including death. The transmitter functions by detecting changes in very weak magnetic fields caused by the rotation of the gears within the flowmeter. Unfortunately it will also respond to stray magnetic fields if they are present. Stray fields can be caused by nearby transformers, relays, solenoids, or AC line energized wiring. For proper operation the transmitter must be located away from these stray fields. The fiberoptic receiver is not designed to be intrinsically safe and must not be mounted in a hazardous (classified) location. If you are unsure about what constitutes a hazardous area please refer to your local electrical codes. W A R N I N G C A U T I O N Installing the transmitter in a location that exposes it to stray magnetic fields will result in improper operation. W A R N I N G Installing the receiver in a hazardous area poses a risk of fire, explosion, and bodily injury up to and including death. INSTALLING THE TRANSMITTER (Onto the Flowmeter) Pick a suitable location as outlined above. Keep in mind the physical fluid connections and the fiberoptic cable connection. The meter / transmitter combination is designed for fluid flow in one primary direction. C A U T I O N The low frequency performance of the transmitter is dependent on the spacing between the pickup and the gear inside the flowmeter. Dirt or debris between the meter and transmitter that increases this distance may result in poor operation of the meter at low flow levels. INSTALLING THE RECEIVER The receiver must be installed in an industrial grade enclosure outside of the hazardous area. Pick a location that is accessible for servicing and where there will be sufficient space for both the electrical wires (3) and the fiberoptic cable. The socket is a standard octal-base relay socket and can either be mounted to a DIN rail using the clips attached to the underside of the base or it can be fastened to a back-plate using the two through holes in the socket. The manufacturer of the sockets may vary so the spacing and size of these holes may vary from installation to installation so dimensions are not provided here. FM

15 Fiberoptic Flowmeter - Installation CONNECTING THE SYSTEM Wiring the Receiver The receiver is connected to the controller via screw terminals on the receiver socket. Only three electrical connections are required. It is highly recommended that this connection be made with shielded cable, 24 AWG or greater. The three connections required are: 1. Terminal #1 should be wired to a regulated 24 VDC power supply, capable of at least 0.25 amp. 2. Terminal #2 should be connected to the common (or ground) of the power supply. This terminal should also be connected to the common of the device that the output signal will drive. 3. Terminal #7 is the output signal. It will output a 1 millisecond long pulse with an amplitude of 24 volts every time it sees a light pulse come in through its fiberoptic connection A Fiberoptic Receiver 1 2 C A U T I O N Treat the connector ends of the fiberoptic cable assembly with care. Be careful not to scratch or otherwise damage the light carrying face of the connector. Protect the connectors if necessary during the installation. C A U T I O N Do not treat the fiberoptic cable like regular copper wire The fiberoptic cable can be damaged if it is bent too sharply. Please observe the minimum bend radius specification during installation. Install the fiberoptic cable as follows: 1. Push the connector end of the cable into the transmitter fiber receptacle until it bottoms. 2. Tighten the retaining nut until snug. 3. Route the fiberoptic cable to the receiver. Secure it as necessary to prevent unwanted movement after installation. Be careful to observe the minimum bend radius specification. White (Source) Red (Phase) Green Black GND +24VDC Shielded cable to controller inputs Figure 5: Receiver Wiring Refer to drawings for controller for terminal and wire numbers 4. It is likely that the standard cable lengths will leave some cable left over. Plan a location where this extra cable can be coiled and stored. When coiling the cable be careful to observe the minimum bend radius specification. 5. At the receiver, connect the cable to the receiver in the same manner as the transmitter. Installing the Typical Fiberoptic Cable The transmitter is connected to the receiver by way of a fiberoptic cable assembly. This cable comes in standard lengths with the fiber connectors already attached. Refer to Table 1 on page 9 for available cable lengths. FM

16 Fiberoptic Flowmeter - Installation SYSTEM VERIFICATION AND TROUBLESHOOTING Verifying a New Installation The fiberoptic transmitter / receiver system contains a diagnostic LED that is located on top of the receiver. This indicator makes it easy to verify proper operation. To verify proper operation perform the following steps: 1. Cause fluid to flow in the meter in the forward direction at a flow rate greater than 10cc/min. 2. Observe the diagnostic LED located on the receiver. The LED will illuminate or flash if it is receiving pulse data from the transmitter. NOTE Flow rates lower than approximately 10cc/min. will not be detected in either forward or reverse direction. 3. The LED verifies the transmitter, fiberoptic cabling, and the receiver circuitry. 4. The system should be functioning normally at this point. If meter fails to function normally, refer to the Troubleshooting section at the back of this manual. FM

17 Fiberoptic Flowmeter - Operation OPERATION GENERAL OPERATION To operate the unit, connect the unit in place per installation instructions. Allow paint to flow through the meter. Read results through appropriate display. CALIBRATION Refer to appropriate associated equipment for calibration procedure. FLOWMETER SERVICING Flowmeter problems can be caused by improperly filtered fluid. Particulates in the fluid can cause gear binding, resulting in improper signals for the actual flow rate. Maintain the fluid filters according to the instructions from the filter manufacturer. If repeated disassembly and cleaning for removal of solids and particulates occurs, inspect the entire fluid supply system and evaluate the system cleaning cycle. C A U T I O N Fluid back-up, that is reverse flow of 2k components, can cause reacted/ catalyzed material to enter the flowmeter. Since these flowmeters are not capable of detecting reverse flow, it is imperitive that check valves be maintained on all plural componant fluid panels 3. Using a 5mm Hex key wrench, remove all the bolts holding the 2 halves of the Flowmeter together. Pull the sensor section STRAIGHT apart from the gear pocket section. Pull the gears and pins from the gear pocket section. Clean and replace worn parts as necessary. C A U T I O N Do not pry the halves of the flowmeter body apart using screwdrivers or other pry tools. (This could damage the flowmeter shaft and bushings, destroying the flowmeter). If the body does not separate easily, replace two (2) of the bolts near the sensor holes and only screw them in two or three threads in the bottom half of the body. Then, hold the top half of the body in your hand and tap on the bolt heads using a soft headed hammer to jar the body halves apart. 4. Install new PTFE O-ring. Install all parts the order they were removed. Install flat portion of shafts toward gears. Push the two (2) covers together, aligning the pins and holes by hand. SERVICE 1. Disconnect fiberoptic cable from transmitter. Remove meter to a suitable area to perform maintenance. 2. Remove the two (2) socket head cap screws on the top of the transmitter using a 3mm Hex key wrench. Figure 6: View of Flat Portion of Shafts FM

18 Fiberoptic Flowmeter - Operation NOTE Flowmeter bodies can be assembled backwards. Insure that the labels on the sides of the two halves of the body are above one another when reassembling the meter. 5. Snug all screws down. Tighten the screws in the sequence pattern shown in Figure 4 to 13 lbs. per ft. torque. This is a cross pattern to insure proper gasket seating. 6. Install transmitter on to body. 7. Reconnect meter into system. FM

19 Fiberoptic Flowmeter - Maintenance MAINTENANCE PREVENTIVE MAINTENANCE The fiber transmitter and receiver are designed to be a rugged and reliable system. Periodic preventative maintenance is not required if flowmeters are properly flushed while not in use. CLEANING THE METER AND TRANSMITTER In some applications the meter is used in an application where the exterior of the meter and transmitter must be periodically cleaned. An example of such an application would be serving as C A U T I O N Do not treat the fiberoptic cable like regular copper wire The fiber cable can be damaged if it is bent too sharply. Please observe the minimum bend radius specification during installation / maintenance. a paint meter in a paint booth system. Cleaning with Water Based Solvents The meter itself is made out of stainless steel and is impervious to water based solvents so that no precautions are necessary with the meter. The transmitter and it s components are enclosed in a nylon enclosure which is highly resistant to water based solvents. As a precaution, avoid the possibility of forcing the cleaning solution into the fiber cable connector or the small gap between the transmitter and the meter. Cleaning with Chemical Based Solvents The meter itself is made out of stainless steel and is impervious to chemical based solvents so that no precautions are necessary with the meter. The transmitter and its components are enclosed in a nylon enclosure that is resistant to chemical solvents such as MEK. When using solvents such as MEK, use as little as possible and keep the contact time with the transmitter as short as possible. Avoid the possibility of forcing the cleaning solvent into the fiberoptic cable connector or the small gap between the transmitter and the meter. AUTOMATIC CLEANING OF THE FLOWMETER Fluid Line Air Purges Air purges are often used in automatic coating operations for rapid color changes and to minimize the amount of solvent required to flush-out the old color. Special considerations must be made when using air purges through the flowmeter. 1. Air purges do not provide the lubrication the flowmeter gears require. Lubrication is normally provided by the metered fluid or solvent. 2. Air purges can cause some coating materials to dry on the flowmeter shafts and gears thus affecting the performance characteristics of the flowmeter, especially when water-based materials are used. 3. Excessively long air purges will cause premature gear and shaft failure. 4. All clean cycles should begin with a solvent push to prevent drying of coating material on flowmeter parts. 5. Solvent and air chop cycles are recommended as the most efficient way of flushing flowmeters. 6. Air purge cycles are not recommended in water-based applications FM

20 Fiberoptic Flowmeter - Maintenance TROUBLESHOOTING GUIDE General Problem Possible Cause Solution NEW INSTALLATION LED on receiver does not pulse. No DC power to the receiver Insufficient fluid flow through the meter No light pulses being emitted by the transmitter (battery may be exhausted) Check receiver wiring. Verify 24 VDC at terminal #1 of J8 on the receiver. Increase fluid flow through the meter. The flow must be greater than 10cc/min. to be detected. The infrared light pulses are not visible to the naked eye. Try swapping sensor with a known good one. Sensor good but no pulses from LED on receiver Fiber cable not fully seated in the connector at transmitter or receiver Fiber connections dirty Defective or damaged fiber cable assembly Reseat the cable in the fiberoptic connector on both ends. Clean them using glass cleaner and a soft cloth or cotton swab. Replace fiberoptic cable assembly LED on the receiver flashes but the controller sees reverse flow On controllers designed to operate with quadrature input signals, the output of the receiver should be connect to the source input. The other (typically called phase or gate) must be connected to +24 VDC a. Rewire the receiver at the controller. b. Correct the receiver output configuration. c. Correct wiring. d. Correct the receiver output configuration. No or erratic operation at low flow rates Transmitter not seated properly on the meter caused by dirt and debris under the transmitter, on the pickups, or in the pickup receptacles. Meter is binding Defective transmitter Clean meter and transmitter mounting surfaces, pickups, and pickup receptacles to eliminate the problem. Replace meter. Replace transmitter. LED flashes with no fluid flowing through the meter Stray magnetic fields are interfering with the transmitter. This may be confirmed by temporarily relocating the transmitter while leaving the fiberoptic cable attached. Relocate the transmitter away from the stray fields or relocate the wiring or equipment generating the stray field away from the transmitter. (Continued On Next Page) FM

21 Fiberoptic Flowmeter - Maintenance TROUBLESHOOTING GUIDE (Cont.) General Problem Possible Cause Solution EXISTING INSTALLATION Receiver LEDs not flashing even with sufficient fluid flow Receiver LEDs not flashing or on continuously with or without fluid flow. Fiberoptic cable has become contaminated from exposure to chemical vapors. Fiberoptic connector interface at the transmitter has become contaminated by ingress of solvent, chemicals, and dirt. Battery is worn out in the transmitter. Confirm by substituting a known good unit. Flow meter gears locked up. Flow meter gears stall due to cleaning solvent / paint incompatibility. Receiver confused by power glitch. Replace the fiberoptic cable. Inspect the optical interface on both the cable and transmitter. A shiny reflection should be seen on the face of the LED in the transmitter. The connector on the end of the fiber cable should also look smooth and clean. Replace damaged components as required. Replace the transmitter. Clean meter, insure proper filtration is use. Consult material manufacturer for proper cleaning solvent. Cycle power to the receiver and/or controller. Poor meter accuracy at low flow rates (meter has never been rebuilt). Gears inside the meter are worn allowing fluid slippage Rebuild the meter and replace the gears and shafts. Poor meter accuracy at low flow rates (meter has previously been rebuilt). Gears and meter chamber are worn allowing fluid slippage Replace the meter and the transmitter as a unit. FM

22 Fiberoptic Flowmeter - Maintenance General Problem Possible Cause Solution EXISTING INSTALLATION (Cont.) Receiver LEDs not flashing or on continuously with or without fluid flow. Receiver confused by power glitch. Cycle power to the receiver and/or controller. Poor meter accuracy at low flow rates (meter has never been rebuilt). Gears inside the meter are worn allowing fluid slippage Rebuild the meter and replace the gears and shafts. Poor meter accuracy at low flow rates (meter has previously been rebuilt). Gears and meter chamber are worn allowing fluid slippage Replace the meter and the transmitter as a unit. FM

23 PARTS IDENTIFICATION Fiberoptic Flowmeter - Parts Identification Figure 6: A Fiberoptic Flowmeter A FIBEROPTIC FLOWMETER - PARTS LIST (Figure 6) Item # Part # Description Qty 1 A12768-XX Fiberoptic Flowmeter Cable Assembly * 1 2 A Sensor Assembly 1 3 M6 X 1 X 30mm L. Socket Head Cap Screws 10 4 N/A Upper Housing 1 5 A Shaft Set (2) 1 6 A Gear Set (2) 1 A TI Coated Gear Set (2) PTFE O-Ring ** 1 8 A Lower Housing 1 9 A Fiberoptic Receiver Assembly 1 * Refer to Table 1 page 9 for available cable lengths. * NOTE: The flowmeters are shipped from the factory with white TFE O-Rings. Replacement O-Rings will be tinted blue to indicate that they are metric, for use in the A13159, A12712, and A12713 flowmeters. FM

24 Fiberoptic Flowmeter - Warranty Policy 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 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, 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, 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 purchaser, therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable. FM

25 Fiberoptic Flowmeter - Warranty Policy Notes: FM

26 Manufacturing 1910 North Wayne Street Angola, Indiana Telephone: Fax: Technical Service Assistance 320 Phillips Ave. Toledo, Ohio Telephone (toll free): Fax: Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Finishing Brands, Inc. All rights reserved. Models and specifications subject to change without notice. Form No. FM Litho in U.S.A. 01/15