Carlisle Ransburg 81545 User manual

Model: 81545 and 81565 RXQ & RFXQ
RansFlex Applicators
IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision AH-17-03-R0 to revision
AH-17-03-R1. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
MANUAL CHANGES
EN
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CONTENTS
SAFETY: 4-8
Safety Precautions ................................................................................................................................................4
Hazards / Safeguards ............................................................................................................................................5
ATEX/FM: 9-17
European ATEX Directive ......................................................................................................................................9
European ATEX Labels .......................................................................................................................................10
FM Conguration Drawings 81545 ......................................................................................................................11
FM Conguration Drawings 81565 ......................................................................................................................14
INTRODUCTION: 18-22
General Description .............................................................................................................................................18
Ransex New Features .......................................................................................................................................18
Specications 81545 ...........................................................................................................................................18
Specications 81565 ...........................................................................................................................................20
Ransex Solventborne Electrostatic Spray Applicator 81545 / 81565 ................................................................21
Typical Solvenborne Installation ..........................................................................................................................22
INSTALLATION: 23-25
81545/81565 Ransex Solventborne Installation ................................................................................................23
General Installation Requirements ......................................................................................................................23
Installation ...........................................................................................................................................................24
OPERATION: 26-33
Applicator Operation ............................................................................................................................................26
Flushing / Color Change Procedure ....................................................................................................................29
Fluid Nozzle / Air Cap ..........................................................................................................................................30
New Nozzle Design .............................................................................................................................................30
Nozzle Selection ..................................................................................................................................................31
Air Cap / Nozzle Performance .............................................................................................................................33
MAINTENANCE: 34-47
Suitable Solvents For Cleaning RansFlex Applicators ........................................................................................34
Routine Schedule ................................................................................................................................................35
Troubleshooting Guide ........................................................................................................................................47
PARTS IDENTIFICATION: 48-67
Ransex RXQ Solvent Base ................................................................................................................................48
Ransex RFXQ Solvent Base .............................................................................................................................50
Items for RXQ (45KV) Unit ..................................................................................................................................53
Items for RFXQ (65KV) Unit ................................................................................................................................55
Handle Components For All Models ....................................................................................................................57
Accessories .........................................................................................................................................................64
Spare Parts Kits ...................................................................................................................................................65
Recommended Spare Parts ................................................................................................................................66
MANUAL CHANGE SUMMARY: 67
Manual Changes .................................................................................................................................................67
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CONTENTS
EN

CAUTION
!
WARNING
!
NOTE
SAFETY PRECAUTIONS
Before operating, maintaining or servicing any electrostatic
coating system , read and understand all of the technical
and safety literature for your 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 specications and service
procedures, some minor deviations may be found between
this literature and your equipment. Differences in local codes
and plant requirements, material delivery requirements, etc.,
make such variations inevitable. Compare this manual with
your system installation drawings and asscoiated equipment
manuals to reconcile such differences.
WARNING
!
WARNING
!
The user MUST read and be familiar with the
Safety Section in this manual and the safety literature
therein identied.
This equipment is intended to be used by
trained personnel ONLY.
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 re codes
and ordinances as well as NFPA-33 AND EN 50177
SAFETY STANDARDS, LATEST EDITION, or
applicable country safety standards, prior to installing,
operating, and/or servicing this equipment.
The hazards shown on the following pages may
occur during the normal use of this equipment.
SAFETY
Repairs may only be performed by authorized personnel.
Careful study and continued use of this manual will provide a
better understanding of the equipment and process, resulting
in more efcient operation, longer trouble-free service and
faster, easier troubleshooting. If you do not have the manuals
and safety literature for your equipment, contact your local
Carlisle Fluid Technologies representative or Carlisle Fluid
Technologies technical support.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area Fire Hazard
Improper or inadequate
operation and maintenance
procedures will cause a re
hazard.
Protection against inadvertent
arcing that is capable of
causing re 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.
Fire extinguishing equipment must be present in the
spray area and tested periodically.
Spray areas must be kept clean to prevent the
accumulation of combustible residues.
Smoking must never be allowed in the spray area.
The high voltage supplied to the atomizer must be
turned off prior to cleaning, ushing or maintenance.
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 ammable 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 modications may cause re or injury.
If used, the key switch bypass is intended for use
only during setup operations. Production should
never be done with safety interlocks disabled.
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.
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Improper or inadequate
operation and maintenance
procedures will cause a
re hazard.
Protection against inadvertent
arcing that is capable of
causing re 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.
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 specically 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 ammable 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 re
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
ushing, cleaning, or working on spray system
equipment.
Before turning high voltage on, make sure no objects
are within the safe sparking distance.
Ensure that the control panel is interlocked with the
ventilation system and conveyor in accordance with
NFPA-33, EN 50176.
Have re extinguishing equipment readily available
and tested periodically.
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 60079-0.
Instructions and safety precautions must be read
and understood prior to using this equipment.
Comply with appropriate local, state, and national
codes governing ventilation, re protection,
operation maintenance, and housekeeping.
Reference OSHA, NFPA-33, EN Norms and your
insurance company requirements.
General Use and
Maintenance
Spray Area Explosion Hazard
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
Spray Area /
High Voltage
Equipment
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 re
or explosion.
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 megohm. (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 ooring must be provided in
the spray area.
Always turn off the power supply prior to ushing,
cleaning, or working on spray system equipment.
Unless specically 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.
Avoid installing an applicator into a uid system
where the solvent supply is ungrounded.
Do not touch the applicator electrode while it is
energized.
Electrical Discharge
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SAFETY
EN

AREA
Tells where hazards
may occur.
HAZARD
Tells what the hazard is.
SAFEGUARDS
Tells how to avoid the hazard.
High voltage equipment is
utilized in the process. Arcing
in the vicinity of ammable or
combustible materials may
occur. Personnel are exposed
to high voltage during operation
and maintenance.
Protection against inadvertent
arcing that may cause a re or
explosion is lost if safety circuits
are disabled during operation.
Frequent power supply shut-
down indicates a problem in
the system which requires
correction.
An electrical arc can ignite
coating materials and cause a
re or explosion.
Unless specically 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 50176.
Turn the power supply OFF before working on the
equipment.
Test only in areas free of ammable 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.
Electrical Discharge
Electrical
Equipment
Certain materials may be
harmful if inhaled, or if there
is contact with the skin.
Follow the requirements of the 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.
Chemical HazardToxic Substances
Spray applicators require that aluminum inlet ttings
be replaced with stainless steel.
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, ushing, or cleaning.
Read the label or data sheet for the material you
intend to spray. If in doubt as to whether or not a
coating or cleaning material is compatible, contact
your coating supplier. Any other type of solvent may
be used with aluminum equipment.
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.
Explosion Hazard —
Incompatible Materials
Spray Area
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SAFETY
EN

EUROPEAN ATEX DIRECTIVE 94/9/EC, ANNEX II, 1.0.6
The following instructions apply to equipment covered by
certicate number Sira 14ATEX5343:
1. The equipment may be used with ammable gases and
vapors with apparatus groups II and with temperature
class T6.
2. The equipment is only certied for use in ambient
temperatures in the range 5°C to +40°C and should
not be used outside this range.
3. Installation shall be carried out by suitably trained
personnel in accordance with the applicable code of
practice e.g. EN 60079-14:1997.
4. Inspection and maintenance of this equipment shall be
carried out by suitably trained personnel in accordance
with the applicable code of practice e.g. EN 60079-17.
5. Repair of this equipment shall be carried out by
suitable trained personnel in accordance with the
applicable code of practice e.g. EN 60079-19.
6. Putting into service, use, assembling, and adjustment
of the equipment shall be tted by suitably trained
personnel in accordance with the manufacturer's
documentation.
Refer to the "Table of Contents" of this service manual:
a. Installation
b. Operation
c. Maintenance
d. Parts Identication
7. Components to be incorporated into or used as
replacement parts of the equipment shall be tted
by suitably trained personnel in accordance with the
manufacturer's documentation.
8. The certication of this equipment relies upon the
following materials used in its construction:
If the equipment is likely to come into contact with
aggressive substances, then it is the responsibility of
the user to take suitable precautions that prevent it
from being adversely affected, thus ensuring that the
type of protection provided by the equipment is not
compromised.
Aggressive substances: e.g. acidic liquids or gases
that may attack metals, or solvents that may affect
polymeric materials.
Suitable precautions: e.g. regular checks as part of
routine inspections or establishing from the material's
data sheets that it is resistant to specic chemicals.
Refer to "Specications" in the "Introduction" section:
a. All uid passages contain stainless steel or nylon
ttings.
b. High voltage cascade is encapsulated with a solvent
resistant epoxy.
9. A recapitulation of the certication marking is detailed in
the "ATEX" section, on the next page, drawing numbers:
81545 and 81565.
10. The characteristics of the equipment shall be detailed
e.g. electrical, pressure, and voltage parameters.
The manufacturer should note that, on being put into
service, the equipment must be accompanied by
a translation of the instructions in the language or
languages of the country in which the equipment is to
be used and by the instructions in the original language.
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ATEX
EN

Ransex 81545/81565 ATEX Product
Marking Denitions
Ex Certicate Number: Sira 14ATEX5343
Sira = Notied Body performing EC-type
examination
14 = Year of certication
ATEX = Reference to ATEX Directive
5 = Protection Concept Code (code 5 is titled
Encapsulation)
343 = Document serial number
X = Special conditions for safe use apply
Special conditions for safe use:
The Ransex 81545/81565 Applicators shall only be used
with associated Ransburg 80558-XX Air Hose Assembly.
It is the end users responsibility to insure the air hose is
properly grounded to true earth ground. Resistance of this
air hose assembly must be .5 MWor less reguardless of
hose length.
Ex = Specic marking of explosive protection
II = Equipment Group hazardous area
characteristics
2 = Equipment Category
G = Type of explosive atmosphere (gases,
vapors, or mists)
EEx 0.24mJ = The Ransex 81545/81565 Applicators are
suitable for use in manual spraying installations complying
with EN 50050 as they are a Type A class with a discharge
energy limit of 0.24mJ.
80777-05
80777-06
FM Conguration
These applicators are FM approved when the setup is
congured to drawings shown on following pages.
II 2 G
Product Marking
80777-07
80777-08
By Ransburg
®
By Ransburg
®
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ATEX
EN