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Ransburg – MCV 2 – Service Manual – CS-05-01.9
- Ransburg - MCV 2 - Service Manual - CS-05-01.9 [ English ]
carefully read SAFETY PRECAUTIONS, starting
on page 1, and all instructions in this manual.
Keep this Service Manual for future reference.
SERVICE MANUAL
CS-05-01.9
(Replaces CS-05-01.8)
March - 2013
MODELS: A10986-XX - English
A10993-XX - Metric
MCV
COLLET SERIES
DUAL PURGE COLOR CHANGER
Service Manual Price: $30.00 (U.S.)
Ransburg
NOTE: This manual has been changed from CS-05-01.8 to revision CS-05-01.9. Reasons for
this change are noted under Manual Change Summary on page 29 of this manual.
MCV 2 Dual Purge Color Changer
CS-05-01.9
Ransburg
GENERAL MAINTENANCE ...................................................................................................15-17
REMOVING AND REINSTALLING A VALVE BLOCK FROM A STACK .................................17
TEST AND CHECKOUT PROCEDURE FOR COLOR CHANGER .......................................18-19
SAFETY: 1-5
SAFETY PRECAUTIONS .......................................................................................................1
HAZARDS / SAFEGUARDS ...................................................................................................2-5
PAGE
INTRODUCTION: 6-10
CONTENTS
DESCRIPTIONS / SPECIFICATIONS ....................................................................................6
A10986-AA PRE-ENGINEERED DUAL PURGE ASSEMBLIES (ENGLISH) / PARTS LIST .........7-8
A10986-AA PRE-ENGINEERED DUAL PURGE ASSEMBLIES
MODEL IDENTIFICATION (ENGLISH) ..................................................................................8
A10993-XX PRE-ENGINEERED DUAL PURGE ASSEMBLIES (METRIC) / PARTS LIST .........9-10
A10993-XX PRE-ENGINEERED DUAL PURGE ASSEMBLIES MODEL
IDENTIFICATION (METRIC)...................................................................................................10
INSTALLATION: 11-12
MCV INSTALLATION PROCEDURES ...................................................................................11-12
OPERATION: 13-14
OPERATING INSTRUCTIONS ...............................................................................................13
DIMENSIONS - METRIC (FRACTION) AND PROPOSED HOOK-UP FOR 2 COLORS ................14
MAINTENANCE: 15-19
PARTS IDENTIFICATION: 20-52
A10986-AA (ENGLISH) AND A10993-XX (METRIC) DUAL PURGE
ASSEMBLIES / PARTS LIST ................................................................................................ 20-21
A10993-XX DUAL PURGE ASSEMBLY (METRIC) / PARTS LIST ........................................ 21
A10984 (ENGLISH) AND A10992 (METRIC) DUAL PURGE SOLVENT /
AIR ASSEMBLY / PARTS LIST.............................................................................................. 22-23
A10981 DUAL PURGE CIRCULATING ASSEMBLY (ENGLISH) / PARTS LIST ................. 24
A10991 DUAL PURGE CIRCULATING ASSEMBLY (METRIC) / PARTS LIST .................... 25
78949-00 VALVE AND 77367-00 SEAT REPLACEMENT PARTS ........................................ 26
77620-00 VALVE PLUG KIT (OPTIONAL) ............................................................................ 26
RECOMMENDED SPART PARTS ........................................................................................ 27
WARRANTY POLICIES: 28
LIMITED WARRANTY ............................................................................................................28
MCV 2 Dual Purge Color Changer - Contents
CS-05-01.9
Ransburg
W A R N I N G!
W A R N I N G!
SAFETY
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any
Ransburg electrostatic coating system, read and
understand all of the technical and safety 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 equip-
ment 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 represen-
tative or Ransburg.
�� The hazards shown on the following pages
may occur during the normal use of this equip-
ment. Please read the hazard chart beginning 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 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.
MCV 2 Dual Purge Color Changer - Safety
1 CS-05-01.9
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Spray Area
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a 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.
MCV 2 Dual Purge Color Changer - Safety
2CS-05-01.9
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area
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.
MCV 2 Dual Purge Color Changer - Safety
3 CS-05-01.9
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AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
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.
MCV 2 Dual Purge Color Changer - Safety
4CS-05-01.9
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Toxic Substances Certain material may be harmful
if inhaled, or if there is contact
with the skin.
Follow the requirements of the Material Safety
Data Sheet supplied by coating material manu-
facturer.
Adequate exhaust must be provided to keep the
air free of accumulations of toxic materials.
Use a mask or respirator whenever there is a
chance of inhaling sprayed materials. The mask
must be compatible with the material being
sprayed and its concentration. Equipment must
be as prescribed by an industrial hygienist or
safety expert, and be NIOSH approved.
AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Electrical
Equipment
Electrical Discharge
High voltage equipment is uti-
lized in the process. Arcing
in the vicinity of 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
MCV 2 Dual Purge Color Changer - Safety
5 CS-05-01.9
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INTRODUCTION
DESCRIPTIONS
The MCV 2 Collet Series Dual Purge Color
Changer is designed with either English or Metric
dual fluid lines to take advantage of the true dual
purge capabilities of the applicators; Evolver and
RMA-202. The design of these applicators allows
the spraying under voltage of one side while the
other side is being cleaned with no loss of voltage
during the spray. Also, included with this assem-
bly is a solvent/air purge block.
The 78949-00 microvalve was designed to trigger
up to 2-million cycles. The fluid and air sections
are separated by a weep port to prevent contam-
ination between air and fluid.
SPECIFICATIONS
Operating Pressure:
Fluid 300 psi max. (20.68 bar)
Operating Temperature
Range: 55°F (12.8°C)
130°F (54°C)
Fluid Tube (Metric):
Inlet 10mm ODT
Circulation 8mm ODT
Solvent/Air Purge 10mm ODT
End Plate Outlet 1/4-inch NPSM AN
Style
Air Tube (Metric):
Actuation 4mm ODT Inlet
Fluid Tube (Fraction):
Inlet 3/8-inch ODT
Circulation 5/16-inch ODT
Solvent/Air Purge 3/8-inch ODT
End Plate Outlet 1/4-inch NPSM AN
Style
Air Tube (Metric-Fraction):
Actuation 5/32-inch
(4mm) ODT Inlet
Air Actuating
Pressure: 75-120 psi (5.2-8.3 bar)
Maximum Number
of Colors: 32
Construction Materials:
Stainless Steel
UHMW
Electrical / Physical
MCV 2 Dual Purge Color Changer - Introduction
6CS-05-01.9
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A10986-AA PRE-ENGINEERED DUAL PURGE
ASSEMBLIES (ENGLISH)
The following is for pre-engineered dual purge assemblies. Please reference A10986-AA
Pre-Engineered Dual Purge Assemblies (English) Parts List for the changer assembly number.
Figure 1: A10986-AA Pre-Engineered Dual Purge Assemblies (English)
EN
G
LI
SH
MCV 2 Dual Purge Color Changer - Introduction
7 CS-05-01.9
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A10986 - AA
Basic Part Number
Quantity of
Color Valves Table AA
TABLE AA
NUMBER OF COLOR VALVES
00
02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
Dash
No. Description
0 Color - Color Changer
2 Color - Color Changer
4 Color - Color Changer
6 Color - Color Changer
8 Color - Color Changer
10 Color - Color Changer
12 Color - Color Changer
14 Color - Color Changer
16 Color - Color Changer
18 Color - Color Changer
20 Color - Color Changer
22 Color - Color Changer
24 Color - Color Changer
26 Color - Color Changer
28 Color - Color Changer
30 Color - Color Changer
32 Color - Color Changer
A
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1 A10984-00 Assembly, Body Dual Purge Solvent/Air, 3/8 1
2 A10981-00 Assembly, Body Dual Purge Circulating, 3/8 See Table AA - A
3 A10979-00 Plate, End Dual Purge 2
4 A11568-00 Adapter, 7/16 AN to 1/4 NPSM 2
5 77957-00 Retaining Clip, Color Changer 1
6 A10985-00 Clip, MCV 2 Dual Purge 2
7 A10977-00 Fitting, Outlet 2
8 79001-05 O-Ring 2
9 78078-00 Tool, Retaining Clip Remove 1
10 A10756-00 Tool, Valve Removal 1
11 A10758-00 Tool, Hose Removal 1
12 A10766-00 Tool, Valve Seat Removal 1
13 A11539-00 Plate, End Dual Purge, Fitting End 1
Item #
A10986-AA PRE-ENGINEERED DUAL PURGE ASSEMBLIES
(ENGLISH) - PARTS LIST (Figure 1)
Part # Description Qty
A10986-AA PRE-ENGINEERED DUAL PURGE
ASSEMBLIES MODEL IDENTIFICATION (ENGLISH)
When ordering, use A10986-AA as indicated by the Table. AA Designates the Number of Color
Valves. Example:
MCV 2 Dual Purge Color Changer - Introduction
8CS-05-01.9
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A10993-XX PRE-ENGINEERED DUAL PURGE
ASSEMBLIES (METRIC)
The following is for pre-engineered dual purge assemblies. Please reference A10993-XX
Pre-Engineered Dual Purge Assemblies (Metric) Parts List for the changer assembly number.
Figure 2: A10993-XX Pre-Engineered Dual Purge Assemblies (Metric)
M
ET
RI
C
MCV 2 Dual Purge Color Changer - Introduction
9 CS-05-01.9
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TABLE AA
NUMBER OF COLOR VALVES
00
02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
Dash
No. Description
0 Color - Color Changer
2 Color - Color Changer
4 Color - Color Changer
6 Color - Color Changer
8 Color - Color Changer
10 Color - Color Changer
12 Color - Color Changer
14 Color - Color Changer
16 Color - Color Changer
18 Color - Color Changer
20 Color - Color Changer
22 Color - Color Changer
24 Color - Color Changer
26 Color - Color Changer
28 Color - Color Changer
30 Color - Color Changer
32 Color - Color Changer
A
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1 A10992-00 Assembly, Body Dual Purge Solvent/Air 10mm 1
2 A10991-00 Assembly, Body Dual Purge Circulating 10mm See Table AA - A
3 A10979-00 Plate, End Dual Purge 1
4 A11568-00 Adapter, 7/16 AN to 1/4 NPSM 2
5 77957-00 Retaining Clip, Color Changer 1
6 A10985-00 Clip, MCV 2 Dual Purge 2
7 A10977-00 Fitting, Outlet 2
8 A11539-00 Plate, End Dual Purge, Fitting End, Metric 1
9 79001-05 O-Ring 2
10 78078-00 Tool, Retaining Clip Remove 1
11 A10756-00 Tool, Valve Removal 1
12 A10758-00 Tool, Hose Removal 1
13 A10766-00 Tool, Valve Seat Removal 1
Item #
A10993-XX PRE-ENGINEERED DUAL PURGE ASSEMBLIES
(METRIC) - PARTS LIST (Figure 2)
Part # Description Qty
A10993 - XX
Basic Part Number
Quantity of
Color Valves Table AA
A10993-XX PRE-ENGINEERED DUAL PURGE
ASSEMBLIES MODEL IDENTIFICATION (Metric)
When ordering, use A10993-AA as indicated by the Table. AA Designates the Number of Color
Valves. Example:
MCV 2 Dual Purge Color Changer - Introduction
10CS-05-01.9
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Determine Location for
Color Changer
The Color Changer should be located as close as
possible to the spray device in order to save paint
and solvent with a color changer. If possible, use
an enclosure to protect the color changer from
airborne paints and solvents.
Calculate Footprint of Color
Changer (See Figure 3)
To calculate the footprint of the color changer add:
• The dimension of the end plate
• The dimension of the purge assembly
• The dimension(s) of the module(s) used to
create the desired number of color valves
• The dimension of the output assembly
Example: To calculate the footprint of a 2-Color
MCV Assembly:
1 (End Plate) + 2-7/16 (purge assembly) +
2-7/16 (2-color valve assembly) + 1 (output
assembly) = 17-3/4.
Mounting the Color Changer
The mounting configurations are as follows
(reference Figure 4):
• 5/16 clearance holes for flush mounting
to the booth wall
INSTALLATION
Figure 3: Calculate Footprint
Figure 4: Mounting the Color Changer
A
B
C
D
MCV INSTALLATION PROCEDURES
1 2 7/16 2 7/16 1
MCV 2 Dual Purge Color Changer - Installation
11 CS-05-01.9
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Figure 5: Grounding the Color Changer
Grounding of the Color Changer
For safety, the color changer MUST be grounded.
Using a 12-gauge wire, ground the output plate
metal mounting screw of the color changer to a
true earth ground. Using an ohm meter, check
for ground, testing the earth ground to the purge
assembly top plate. The resistance should be 10
ohms or less (see Figure 5).
> The color changer MUST be properly
grounded. Proper grounding (as described
below) will prevent static charge buildup and
possible discharge from the color changer.
W A R N I N G!
NOTE
> Use metal screws for mounting for
grounding purposes.
END PLATE BOLT
OHMS
EARTH GROUND
(TRUE)
10 0
MCV 2 Dual Purge Color Changer - Installation
12CS-05-01.9
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OPERATION
OPERATING
INSTRUCTIONS
Each slice of the block contains 2 colors, one for
each side of the slice. There are two valves on
each side which are daisy chained internally. This
allows one inbound color line and one outbound
color line run from a paint supply to the dual
purge stack rather than two lines and two returns
for each color. This design uses half the tubing
normally needed for the dual purge applications.
However, there are two (2) 4mm ODT trigger lines
to open the valves to feed line A or line B.
The stack should be mounted as close to the
applicator as possible to minimize the waste ma-
terial left in the tube between the stack and the
applicator. An air push may be used to minimize
the material waste. However, this requires the
applicator to have a regulator on-board to control
the fluid pressure and flow to the applicator while
air is pushing. Both the Evolver and the RMA-202
have optional on-board fluid regulators available.
The normal function would be to have only one
trigger open at a time per side A or B. If more than
one trigger is opened per side, material contam-
ination will occur. The exception is the solvent
air chop that is required for cleaning the internal
porting of the stack.
An example is while Color 1 Trigger A is actuated
which would be supplying an applicator, side B is
being cleaned from the purge stack to the dump
of the applicator. Once cleaning is complete, any
color may be loaded into line B.
Figure 6 shows a typical Color Changer Schemat-
ics to prevent back flow of material.
Figure 6: Color Changer Schematics
FLOW METER FLOW METER
LINE A LINE B
FLUID REGULATOR
LINE A
FLUID REGULATOR
LINE B
CO
LO
R 2 O
U
T
CO
LO
R 2 IN
CO
LO
R 1 IN
CO
LO
R 1 O
U
T
SO
LVEN
T
MCV II DUAL PURGE
M
AIN
AIR
SPRAY DEVICE
LINE A
SPRAY DEVICE
LINE B
SPRAY DEVICE
MCV 2 Dual Purge Color Changer - Operation
13 CS-05-01.9
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Figure 7: Dimensions-Metric (Fraction) and Proposed Hook-Up
DIMENSIONS - METRIC (FRACTION) AND PROPOSED
HOOK-UP FOR 2 COLORS
COLOR 2 IN
COLOR 2 OUT
SOLVENT IN
TRIGGER COLOR 2B
TRIGGER COLOR 2A
OUTLET A
OUTLET B
TRIGGER SOLVENT B
TRIGGER SOLVENT A
COLOR 1 IN
COLOR 1 OUT
TRIGGER COLOR 1B
TRIGGER COLOR 1A
AIR IN
TRIGGER AIR B
TRIGGER AIR A
83.62
Ø 9.93 [Ø 0.391 in]
TYP.
161.93
62.15
[2.447 in]
[6.375 in]
[3.292 in]
MCV 2 Dual Purge Color Changer - Operation
14CS-05-01.9
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MAINTENANCE
Figure 9: Seat Removal
Figure 8: Valve RemovalNOTE
> When replacing or repairing any compo-
nents in this system, before reassembling,
apply a light coat of food grade
petroleum jelly to all o-rings.
GENERAL MAINTENANCE
> Prior to servicing the unit, insure that all
fluid pressure is relieved to atomsphere. A
solvent purge should be performed if pos-
sible.
W A R N I N G!
NOTE
> This procedure allows valve and/or seat
removal without removing the valve slice
from the assembly.
Value and Seat Removal
To remove the valve for any reason, insert the
(4) prongs from the tool into the holes on the top
the Microvalve. Using a 1/2 socket, adjustable
wrench or a combination box open end wrench,
turn counter-clockwise to remove the valve.
To remove the seat, insert the seat removal tool
into the seat and turn counter-clockwise using a
3/8 socket, adjustable wrench or combination
box open end wrench.
MCV 2 Dual Purge Color Changer - Maintenance
15 CS-05-01.9
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To reinstall, tighten the valve seat first using the
tool by hand. Then using a torque wrench with a
3/8’ socket, tighten the seat in place, clockwise
in direction to 15-20 lbs•in torque.
Tube Insertion
Prior to inserting the tube, remove the red clip un-
der the collet. Insert the tube into the stack collet
by grasping the tube about 2-4-inches from the
chamfered end. Press the tube all the way down
in the collet until it cannot be pressed any further,
the tube must pass by both o-rings. Each tube
must be inserted into its mating collet to the proper
depth as shown in the chart below. With the tube
inserted, pull the collet up enough to slide the clip
under the collet.
Figure 11: Microvalve Installation
> Be careful not to cross thread the parts
when reassembling. Could cause permanent
damage to block.
C A U T I O N!
> Not using a torque wrench for seat instal-
lation may cause permanent damage to the
seal pocket of the valve block.
C A U T I O N!
Figure 10: Reinstall Valve and Seat
To install the Microvalve, tighten the valve into
the pocket using the provided tool and a 1/2
wrench or socket clockwise until the valve has
just about seated. Then using a torque wrench
tighten to 15-20 lbs•in.
3/8 or 10mm 3/4 or 19.0mm
5/16 or 8mm 11/16 or 17.5mm
5/32 or 4mm 5/8 or 16.0mm
Tube OD Tube Depth
MCV 2 Dual Purge Color Changer - Maintenance
16CS-05-01.9
Ransburg
> Be careful of residual fluid pressure or
solvent pressure in the line. Cover the area
where the valve slice is being removed to
prevent any solvent or paint from spraying
out.
W A R N I N G!
4. Pull out the 1/2-inch clip as shown in Figure 13.
5. Loosen and remove any mounting bolts hold-
ing the stack in place.
6. Carefully pull the stack assembly ends apart
and remove the valve block.
> Prior to servicing the unit, insure that all
fluid pressure is relieved to atomsphere. A
solvent purge should be performed if pos-
sible.
W A R N I N G!
Figure 12: Tube Removal
Tube Removal
The 5/32-inch (4mm) trigger line tubes may be
removed by hand by pushing on the collet while
pulling out the tube. A tool is required to remove
both the 5/16-inch (8mm) and 3/8-inch (10mm)
tube. To remove the 10mm tube, use the black
inserted end of the tool. For the 8mm tube, use
the white inserted end. First remove the red clips
then press the tool against the collet in the block.
With the collet pushed in , pull out the tube that
is being removed (see Figure 12).
TUBING
REMOVING AND
REINSTALLING A VALVE
BLOCK FROM A STACK
1. Insure all pressure is bled off the system. If
possible, flush the block with appropriate solvent.
2. Using the clip removal tool (78078-00), push
on the installed locking clip with the V cut as
shown in Figure 13.
3. Push the upper locking clip out of the locking
slots using the removal tool.
7. Replace the valve slice, push the assembly
together, and insert the locking clips.
Figure 13: Removing and Reinstalling Valve
Block from a Stack
MCV 2 Dual Purge Color Changer - Maintenance
17 CS-05-01.9
Ransburg
NOTE
> If bubbles are observed, dismantle color
changer manifold and repair as required.
TEST AND CHECKOUT
PROCEDURE FOR COLOR
CHANGER
Step 1:
1. Connect air line to a regulated air supply.
2. Attach the air line to a ball valve assembled to
the outlet of the color changer.
3. Adjust the air supply pressure to 100 psi (6.9 bar).
4. Open the ball valve at the outlet of the color
changer.
5. Apply a soap solution on the color changer
manifold.
6. Check the manifold assembly’s mating sur-
faces between color blocks for soap bubbles.
7. If no bubbles are present, rinse manifold with
water and blow dry with air.
Step 2:
1. Attach two (2) regulated air supply hoses, one
with a 3-way valve (normally closed) for operating
the color valve cylinder on the color changer. (Set
the pressure to the 3-way valve at 75 psi (5.8 bar)
or more.)
The second hose will be used for supplying 100
psi (6.9 bar) of air to the color inlet port of each
color changer valve.
2. Connect the air supply hose with 100 psi (6.9
bar) to color inlet valve. Connect a 2-way ball
valve to the matching return port on the color
changer manifold.
3. Turn the ball valve installed on the paint circu-
lation fitting to verify recirculation ability.
4. Connect the air supply with a 3-way valve
(normally closed) to the color valve cylinder.
5. Activate the 3-way valve to operate the color
valve.
6. Deactivate the 3-way valve and close the
color valves.
7. Connect a 1/4-inch (6.4 cm) ID hose 3-feet
(91.4cm) long to the outlet of the color changer.
8. Acquire a container of water and fill it with
about 4-inches (10.6 cm) of WATER.
Position the hose in the container filled with
water.
NOTE
> Ensure valve is closed when completed.
NOTE
> The piston rod on the top of the color
valve assembly should EXTEND and air
should blow out of the color changer outlet.
Check for a crisp and sharp actuation of
the color valve air cylinder.
NOTE
> The piston rod on the top of the color
valve assembly should be RETRACTED,
and the air should have stopped blowing
out of the outlet of the color changer.
MCV 2 Dual Purge Color Changer - Maintenance
18CS-05-01.9
Ransburg
Figure 14: Ground Test
> ALWAYS test color changer for con-
ductivity after assembly or repair. Proper
conductivity is required to assure entire
color changer can be properly grounded
when installed.
> NEVER wrap the equipment in plastic to
keep it clean. A surface charge may build-up
on the plastic surface and discharge to the
nearest grounded object. Efficiency of the
equipment will also be reduced and damage
or failure of the equipment’s components
may occur. WRAPPING THE EQUIPMENT
in plastic will void warranty.
W A R N I N G!
W A R N I N G!
9. There should be no more than 6 bubbles
per minute coming from the outlet of the hose
that is submerged.
10. If there are more than 6 bubbles per minute,
remove the color valve assemby, replace the
valve seat (77367-00) and reinstall color valve
assembly. If the new seat does not correct the
problem, either the manifold block or color valve
assembly is defective.
11. Proceed to the next color valve and repeat
Steps 2 thru 11.
12. When all the color valves are checked out,
then check the purge valve assembly repeating
Steps 2 thru 11.
13. Once all valves are operational, deactivate
the 3-way valve, and then disconnect the air
lines used for testing from the color changer.
14. With an ohm meter, check for conductivity
between the top plate of the purge valve and
the output plate on the color changer. There
should be 10 ohms or less between the two
points (see Figure 14).
END PLATE BOLT
OHMS
EARTH GROUND
(TRUE)
10 0
MCV 2 Dual Purge Color Changer - Maintenance
19 CS-05-01.9
Ransburg
Figure 15: A10986-AA (English) and A10993-XX (Metric) Dual Purge Assemblies
PARTS IDENTIFICATION
M
ET
RI
C
EN
G
LI
SH
MCV 2 Dual Purge Color Changer - Parts Identification
20CS-05-01.9
Ransburg
1 A10992-00 Assembly, Body Dual Purge Solvent/Air, 10mm 1
2 A10991-00 Assembly, Body Dual Purge Circulating, 10mm See Table AA - A
3 A10979-00 Plate, End Dual Purge 1
4 A11568-00 Adapter, 7/16 AN to 1/4 NPSM 2
5 77957-00 Retaining Clip, Color Changer 1
6 A10985-00 Clip, MCV 2 Dual Purge 2
7 A10977-00 Fitting, Outlet 2
8 A11539-00 Plate, End Dual Purge, Fitting End, Metric 1
9 79001-05 O-Ring 2
TABLE AA
NUMBER OF COLOR VALVES
00
02
04
06
08
10
12
14
16
18
20
22
24
26
28
30
32
Dash
No. Description
0 Color - Color Changer
2 Color - Color Changer
4 Color - Color Changer
6 Color - Color Changer
8 Color - Color Changer
10 Color - Color Changer
12 Color - Color Changer
14 Color - Color Changer
16 Color - Color Changer
18 Color - Color Changer
20 Color - Color Changer
22 Color - Color Changer
24 Color - Color Changer
26 Color - Color Changer
28 Color - Color Changer
30 Color - Color Changer
32 Color - Color Changer
A
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Item #
A10993-XX DUAL PURGE ASSEMBLY (METRIC) - PARTS LIST (Figure 15)
Part # Description Qty
1 A10984-00 Assembly, Body Dual Purge Solvent/Air, 3/8 1
2 A10981-00 Assembly, Body Dual Purge Circulating, 3/8 See Table AA - A
3 A10979-00 Plate, End Dual Purge 2
4 A11568-00 Adapter, 7/16 AN to 1/4 NPSM 2
5 77957-00 Retaining Clip, Color Changer 1
6 A10985-00 Clip, MCV 2 Dual Purge 2
7 A10977-00 Fitting, Outlet 2
8 A11539-00 Plate, End Dual Purge, Fitting End 1
9 79001-05 O-Ring 2
Item #
A10986-AA DUAL PURGE ASSEMBLY (ENGLISH) - PARTS LIST (Figure 15)
Part # Description Qty
MCV 2 Dual Purge Color Changer - Parts Identification
21 CS-05-01.9
Ransburg
Figure 16: A10984 (English) and A10992 (Metric) Dual Purge Solvent / Air Assembly
5
2
1
9
6
7
12
811
10
3
5
13
4
14
MCV 2 Dual Purge Color Changer - Parts Identification
22CS-05-01.9
Ransburg
1 A10983-00 Assembly, Body Dual Purge Solvent/Air, 3/8 1
2 77367-00 Assembly, Valve Seat 4
3 78949-00 Assembly, Valve 4
4 78944-00 Assembly, Check Valve 2
5 79001-06 O-Ring, Solvent Proof 4
6 77762-05 Collet, Tube Fitting, 3/8 2
7 79001-24 O-Ring, Solvent Proof 4
8 79001-30 O-Ring, Solvent Proof 4
9 77516-04 Collet, 5/32 4
10 A10985-00 Clip, MCV 2 Dual Purge 2
11 77957-00 Retaining Clip, Color Changer 1
12 A10824-00 Red Locking Clip, 3/8 OD Tube 2
13 78947-00 Seal 2
14 78945-00 Plug, Check Valve 2
1 A10990-00 Assembly, Body Dual Purge Solvent/Air, 10mm 1
2 77367-00 Assembly, Valve Seat 4
3 78949-00 Assembly, Valve 4
4 78944-00 Assembly, Check Valve 2
5 79001-06 O-Ring, Solvent Proof 4
6 77762-02 Collet, Tube Fitting, 10mm 2
7 79001-31 O-Ring, Solvent Proof 4
8 79001-30 O-Ring, Solvent Proof 4
9 77516-04 Collet, 4mm 4
10 A10985-00 Clip, MCV 2 Dual Purge 2
11 77957-00 Retaining Clip, Color Changer 1
12 A10824-00 Red Locking Clip, 10mm OD Tube 2
13 78947-00 Seal 2
14 78945-00 Plug, Check Valve 2
Item #
A10992 DUAL PURGE SOLVENT / AIR ASSEMBLY
(METRIC) - PARTS LIST (Figure 16)
Part # Description Qty
Item #
A10984 DUAL PURGE SOLVENT / AIR ASSEMBLY
(ENGLISH) - PARTS LIST (Figure 16)
Part # Description Qty
MCV 2 Dual Purge Color Changer - Parts Identification
23 CS-05-01.9
Ransburg
Figure 17: A10981 Dual Purge Circulating Assembly (English)
1 A10989-00 Assembly, Body Dual Purge Circulating/Air, 3/8 1
2 77367-00 Assembly, Valve Seat 4
3 78949-00 Assembly, Valve 4
4 79001-05 O-Ring, Solvent Proof 2
5 79001-06 O-Ring, Solvent Proof 2
6 77516-02 Collet, Tube Fitting, 3/8 2
7 79001-24 O-Ring, Solvent Proof 4
8 79001-30 O-Ring, Solvent Proof 4
9 77516-04 Collet, 5/32 4
10 77957-00 Retaining Clip, Color Changer 1
11 A10985-00 Clip, MCV 2 Dual Purge 2
12 A10824-00 Red Locking Clip, 3/8 OD Tube 4
13 A10825-00 Red Locking Clip, 1/4 OD Tube 2
14 77762-04 Collet, Tube Fitting, 5/16 2
15 79001-34 O-Ring, Solvent Proof 4
Item #
A10981 DUAL PURGE CIRCULATING ASSEMBLY
(ENGLISH) - PARTS LIST (Figure 17)
Part # Description Qty
5
2
3
9
8
6
13
15
1
11
10
4
7
12
14
MCV 2 Dual Purge Color Changer - Parts Identification
24CS-05-01.9
Ransburg
Figure 18: A10991 Dual Purge Circulating Assembly (Metric)
1 A10989-00 Assembly, Body Dual Purge Circulating/Air, 10mm 1
2 77367-00 Assembly, Valve Seat 4
3 78949-00 Assembly, Valve 4
4 79001-05 O-Ring, Solvent Proof 2
5 79001-06 O-Ring, Solvent Proof 2
6 77762-02 Collet, Tube Fitting, 10mm 2
7 79001-31 O-Ring, Solvent Proof 4
8 79001-30 O-Ring, Solvent Proof 4
9 77516-04 Collet, 4mm 4
10 77957-00 Retaining Clip, Color Changer 1
11 A10985-00 Clip, MCV 2 Dual Purge 2
12 A10824-00 Red Locking Clip, 10mm OD Tube 4
13 A10825-00 Red Locking Clip, 8mm OD Tube 2
14 77762-04 Collet, Tube Fitting, 8mm 2
15 79001-34 O-Ring, Solvent Proof 4
Item #
A10991 DUAL PURGE CIRCULATING ASSEMBLY
(METRIC) - PARTS LIST (Figure 18)
Part # Description Qty
5
2
3
9
8
6
13
15
1
11
14 4
12
7
10
MCV 2 Dual Purge Color Changer - Parts Identification
25 CS-05-01.9
Ransburg
1 79001-01 O-Ring, Solvent Proof 1
2 79001-02 O-Ring, Solvent Proof 2
3 79001-14 O-Ring, Solvent Proof 1
Item #
78949-00 VALVE & 77367-00 SEAT REPLACEMENT PARTS
(Figure 19a)
1 79244-00 Plug 1
2 79001-19 O-Ring, Solvent Proof 1
3 79001-14 O-Ring, Solvent Proof 1
4 77618-00 Plug, Seat 1
Item #
77620 VALVE PLUG KIT (Optional)
(Use in place of Valve & Seat) (Figure 19b)
Part # Description Qty
Part # Description Qty
Figure 19a: 78949-00 Valve & 77367-00 Seat Replacement Parts
Figure 19b: 77620-00 Valve Plug Kit (Optional)
3
2
1
2
MCV 2 Dual Purge Color Changer - Parts Identification
26CS-05-01.9
Ransburg
77957-00 Retaining Clip
A10824-00 Locking Clip
A10825-00 Locking Clip
79001-05 O-Ring, Solvent Proof
79001-06 O-Ring, Solvent Proof
RECOMMENDED SPARE PARTS
Part # Description
MCV 2 Dual Purge Color Changer - Parts Identification
27 CS-05-01.9
Ransburg
WARRANTY POLICIES
LIMITED WARRANTY
Ransburg will replace or repair without charge
any part and/or equipment that fails within the
specified time (see below) because of faulty work-
manship or material, provided that the equipment
has been used and maintained in accordance with
Ransburg’s written safety and operating instruc-
tions, and has been used under normal operating
conditions. Normal wear items are excluded.
THE USE OF OTHER THAN RANSBURG AP-
PROVED 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, (examples: guns, power supplies, control
units, etc.), is one (1) year from date of purchase.
WRAPPING THE APPLICATOR, ASSOCIATED
VALVES AND TUBING, AND SUPPORTING
HARDWARE IN PLASTIC, SHRINK-WRAP,
OR ANY OTHR NON-APPROVED COVERING,
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.
MCV 2 Dual Purge Color Changer - Warrant Policies
28CS-05-01.9
Ransburg
This manual was published to replace Service Manual CS-05-01.8, MCV 2 Collet
Series Dual Purge Color Changer to make the following changes:
1. Change logo.
MANUAL CHANGE SUMMARY
MCV 2 Dual Purge Color Changer - Safety
29 CS-05-01.9
Ransburg
Form No. CS-05-01.9
Litho in U.S.A.
03/13
© 2013 Ransburg. All rights reserved.
Models and specifications subject to change without notice.
Manufacturing
1910 North Wayne Street
Angola, Indiana 46703-9100
Telephone: 260/665-8800
Fax: 260/665-8516
Technical/Service Assistance
Telephone: 800/ 233-3366
Fax: 419/ 470-2071
www.ransburg.com
Technical Support Representative will direct you to the appropriate
telephone number for ordering Spare Parts.
Service Manual Price: $30.00 (U.S.)
