Carlisle Ransburg RansFlex RFXi Series User manual

IMPORTANT: Before using this equipment, carefully read SAFETY PRECAUTIONS and all
instructions in this manual. Keep this Service Manual for future reference.
Model: 81465 RFXi
RansFlex Applicators for In-Direct
Charge Waterbased Applicators
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EN
SERVICE MANUAL

NOTE: This manual has been changed from revision AH-17-02-R0 to revision
AH-17-02-R1. Reasons for this change are noted under “Manual Change
Summary” inside the back cover of this manual.
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MANUAL CHANGES
EN

CONTENTS
SAFETY: 4-8
Safety Precautions ................................................................................................................................................4
Hazards / Safegaurds ............................................................................................................................................5
ATEX/FM REQUIREMENTS: 9-12
Ransex RFXi - Waterbase Only .........................................................................................................................10
Available Accessories...........................................................................................................................................11
INTRODUCTION: 13-16
General Description .............................................................................................................................................13
Ransex New Features .......................................................................................................................................13
Specications 81465 Ransex Indirect Charge Waterbase ................................................................................14
Typical Installation ...............................................................................................................................................16
INSTALLATION: 17-19
81465 Ransex Indirect Charge Waterborne Installation ....................................................................................17
General Installation Requirements ......................................................................................................................17
Installation ...........................................................................................................................................................18
OPERATION: 20-24
Applicator Operation ............................................................................................................................................20
Flushing / Color Change Procedure ....................................................................................................................23
Fluid Nozzle / Air Cap ..........................................................................................................................................23
New Nozzle Design .............................................................................................................................................24
Air Cap / Nozzle Performance .............................................................................................................................24
MAINTENANCE: 25-38
Suitable Solvents For Cleaning RansFlex Applicators ........................................................................................25
Routine Schedule ................................................................................................................................................26
Troubleshooting Guide ........................................................................................................................................38
PARTS IDENTIFICATION: 39-55
Ransex RFXi Indirect Charge Waterbase ..........................................................................................................39
Items for RFXi (65KV) Unit ..................................................................................................................................43
Handle Components For All Models ....................................................................................................................44
Accessories .........................................................................................................................................................51
Spare Parts Kits ...................................................................................................................................................52
Recommended Spare Parts ................................................................................................................................53
MANUAL CHANGE SUMMARY: 54
Manual Changes .................................................................................................................................................54
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CONTENTS
EN

SAFETY
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.
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

Label 80777-09
Requirements
These applicators are FM approved when the product
setup is congured to drawings shown on the following
pages. This product is approved for use only with non-
ammable water-based materials when the materials
meet the FM denition for a waterbased spray material*.
It is the end users’ responsibility to insure the material that
is sprayed meets this requirement.
Label 80777-10
* FM 7260 waterbased spray material - a material that
does not sustain burning when tested in accordance with
ASTM D 4206.
Atex Requirements
This product provides an indirect charge to water based
materials that will improve the transfer efciency over
non-electrostatic products. Because it is In-Direct charge,
the uid delivery system may be completely grounded
from the source all the way to the applicator. Because this
product uses water based materials only, there may be no
requirement for an ATEX approval. As long as the material
being used meets the ammability denition as stated in
EN 50059: 1991**, there is no hazardous area that must
ATEX REQUIREMENTS
FM REQUIREMENTS
be zoned around the applicator. No ATEX approval is
required. It is the end users responsibility to insure all of
these conditions are met.
**EN 50059: 1991 Denition of non-ammable
spraying material
The material applied by means of electrostatic hand held
spraying equipment and which cannot be ignited, when in
any mixture with air, by an energy source less than 500 mJ.
By Ransburg
®
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ATEX
EN

RANSFLEX RFXi - WATERBASE ONLY
81465 -
Base
Model No.
Optional
Designations
ABCDEF
(Ordering Information Only)
CONFIGURATION DWG. 81466-00
REV. A
F
E
D
A
C
B
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ATEX
EN

0 T SERIES 1.2mm 80383-00 80239-12 74963-05
1 T SERIES 1.4mm 80383-00 80239-14 74963-05
2 T SERIES 1.8mm 80383-00 80239-18 74963-05
3 T SERIES 1.0mm 80383-00 80239-10 74963-05
4 T SERIES 0.7mm 80383-00 80239-07 74963-05
“S” (Fluid Nozzle) “T” (Pressure Reducer)“R” (Air Cap)
80211-00 “V”
80262-01 “U” 80262-00 “U”
1 ADJUSTABLE FLUID 80262-00
2 NON-ADJUSTABLE FLUID 80262-01
“B” Dash No. “B” Description
FLUID CONTROL - TABLE OF “B” DASHES
“U”
“C” Dash No. “C” Description “V”
1 2 FINGER TRIGGER 80211-00
2 4 FINGER TRIGGER 80386-00
3 2 FINGER SMALL PROFILE 80566-00
TRIGGER - TABLE OF “C” DASHES
“A” Dash No. “A” Description
ATOMIZATION - TABLE OF “A” DASHES
“R” “S” “T”
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ATEX
EN

80868-00
80303-XX “X” 80558-XX “Y”
80869-00
“Z”
80269-45
“W”
1 STD FLUID INLET TUBE 80269-45
“D” Dash No. “D” Description
FLUID INLET - TABLE OF “D” DASHES
“W”
0 NO FLUID HOSE ---
1 FLUID HOSE, 10m 80303-10
2 FLUID HOSE, 15m 80303-15
3 FLUID HOSE, 20m 80303-20
4 FLUID HOSE, 30m 80303-30
“E” Dash No. “E” Description
FLUID HOSE - TABLE OF “E” DASHES
“X”
“F” Dash No. “F” Description
AIR HOSE - TABLE OF “F” DASHES
“Z”“Y”
0 NO AIR HOSE, STANDARD --- 80868-00
1 STANDARD AIR HOSE, 5m 80558-05 80868-00
2 STANDARD AIR HOSE, 10m 80558-10 80868-00
3 STANDARD AIR HOSE, 15m 80558-15 80868-00
4 STANDARD AIR HOSE, 20m 80558-20 80868-00
5 NO AIR HOSE, QD --- 80869-00
6 QD AIR HOSE, 5m 80558-06 80869-00
7 QD AIR HOSE, 10m 80558-11 80869-00
8 QD AIR HOSE, 15m 80558-16 80869-00
9 QD AIR HOSE, 20m 80558-21 80869-00
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ATEX
EN

RANSFLEX NEW FEATURES
• Light weight and easy to maneuver.
• Ergonomic handle design to reduce
operator fatigue.
• Three phases of turbine protection:
- Divorced turbine air supply cartridge
- Sealed nozzle/Atomization passages
- Strategic turbine location
• DeVilbiss spray technology integration
into atomization.
• Simultaneous fan/atom pressure adjustment with
compensation valve.
GENERAL DESCRIPTION
The Ransex is an air atomizing applicator powered only
by a pressurized air source. Pressurized air creates rotation
of a turbine generator that powers a cascade. The cascade
generates a high voltage DC charge to the electrode creating
an electrostatic eld between the atomizer and the target.
One of the many features of the Ransex applicator system
is that the electrical energy, which is available from the
resistive charging electrode, is limited to the optimum level
of safety and efciency. The system is incapable of releasing
sufcient electrical or thermal energy during normal
operating conditions to cause ignition of specic hazardous
materials in their most easily ignited concentrations in air.
As the applicator electrode approaches ground, applicator
circuitry causes the high voltage to approach zero while the
current approaches its maximum value. This performance
is validated by independent test agencies that give ATEX
EN 50050 approvals or FM 7260 approvals.
This Ransex model is designed specically for indirect
charge waterbase applications only. The design eliminates
the need for isolation equipment normally needed for use
with electrostatic waterborne applications.
The water base materials must be classied as non-amable
spray material. This means the mixture with air cannot be
ignited by an energy source less than 500 mJ.
INTRODUCTION
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INTRODUCTION
EN

SPECIFICATIONS:
81465 RANSFLEX INDIRECT CHARGE WATERBASE
Fluid Flow Capacity: 1000 ml/minute**
Wetted Parts: Stainless, polyethylene, nylon, acetal polymer
Operating Pressure (Air Spray)
Fluid: (0-6.9 bar) 0-100 psi
Air: (0-6.9 bar) 0-100 psi
Ambient Temp.: 40°C to 5°C (104°F to 32°F)
Consumption (With Voltage): 438 SLPM (15.4 SCFM) @ 2.8 bar (40 psig) @ Handle Inlet
Sound Level: 92dB (A) @ 2.8 bar (40 psig) Inlet, 1m from applicator
Applicator Length: 254mm (10-inches)
Weight: (Without Hose) 600 grams (21.3 oz.)
Hose 80558-XX Lengths (Std): 5m, 10m, 15m and 20m
Operating Voltage: 65kV DC (-) maximum
Current Output: 120 microamperes maximum
Paint Resistance:* Waterbase paint only with grounded source
Part Sprayability: Determine sprayability of part to be coated using 76652, Test Equipment
Environmental/Physical
Electrical
Mechanical
** This reects the maximum uid volume the applicator can deliver. The maximum spray volume that can be effectively
atomized depends on uid rheology, spray technology, and nish quality required.
* Use Model No. 76652, Test Equipment
(See current “Paint, HV & SCI Test Equipment” service manual TE-98-01)
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INTRODUCTION
EN

Figure 1: Ransex Indirect Charge Waterborne Electrostatic Spray Applicator 81465
1
2
3
10
11
9
4
5
7
6
8
12
1 Needle/Electrode
2 Barrel
3 Handle
4 Fan Adjustment
5 Fluid Adjustment
6 Air Hose
No. Description No. Description
7 Exhaust Air Hose
8 Fluid Hose
9 Voltage On/Off Switch
10 Trigger
11 Compensation Valve
12 Air Cap with Charging Electrodes / Fluid Nozzle
RANSFLEX INDIRECT CHARGE WATERBORNE ELECTROSTATIC
SPRAY APPLICATOR 81465
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INTRODUCTION
EN

No. Description No. Description
1 Ransex 81465
2 Ball Valve
3 Air Regulator with Pressure Gauge
4 Air / Water Separator
5 Main Air Supply Line
6 Fluid Supply (Grounded)
7 Fluid Regulator
8 Air Hose (80558-XX)
9 Air Hose Ground Wire
10 Fluid Line
Figure 2: Ransex Installation for Waterbase Materials
5
4
3 2
3
27
6
9
10
8
1
RANSFLEX INDIRECT CHARGE WATERBASE TYPICAL INSTALLATION
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INTRODUCTION
EN

INSTALLATION
Fluid Hose Recommendation
Ransburg recommends using a 80303-XX Fluid Hose
Assembly. This assembly is made to specically t the
uid tting size engineered into the applicator. This hose
is available from your authorized Ransburg distributor.
Available hose lengths are listed in "Accessories" in the
"Parts Identication" section of this manual.
Filters
1. Install an air lter assembly on the outlet of the main air
regulator. The lter should be 5 micron with a maximum
working pressure of at least 100 psig (6.9 bar). For
Class 3 air quality, which is a 5 micron size and has a
dew point of -4°F (-20°C), the relative humidity (RH) of
the air should be 5%.
2. Ransburg recommends that a uid lter be installed at the
output of the uid supply (pressure pot, pump, circulating
system, etc.). It is the end user's responsibility to install
the proper lter that meets their system's requirements.
81465 RANSFLEX INDIRECT
CHARGE WATERBORNE
INSTALLATION
GENERAL INSTALLATION
REQUIREMENTS
1. Operator must make skin contact with handle of
applicator. If gloves are required use either gloves
with palm and nger cut out or conductive gloves. See
accessory pages for conductive gloves.
WARNING
!
Air Hose
Any user installed uid hose used must be rated
for (100 psig) 6.9 bar working pressure minimum.
For proper safe function of the applicator, the
80558-XX Air Hose Assembly must be used (either
standard or quick disconnect style).
WARNING
!
CAUTION
!
The user MUST read and be familiar with the
"Safety" section of this manual.
This hand held device 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 requirements for
operating and servicing safely are followed. The user
should be aware of and adhere to ALL local building
and re codes and ordinances as well as NFPA,
OSHA, and all related country safety codes prior to
installing, operating, and/or servicing this equipment.
Personnel MUST be GROUNDED to prevent a
shock or spark during electrostatic operation.
Install and route the hoses so they are NOT
exposed to temperatures in excess of 120° F (49°
C) and so that all hose bends are NO LESS than a
6-inch (15cm) radius. Failure to comply with these
parameters could cause equipment malfunction that
might create HAZARDOUS CONDITIONS!
WARNING
!
This applicator is for use with non-amable water base
materials only. The material when atomized cannot be
ignited by an energy greater than 500mJ. Consult your paint
supplier to insure your material meets these reqirements.
Material that will not sustain burning when tested in
accordance with ASTM D 4206.
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INSTALLATION
EN

2. All objects inside spray area must be grounded - refer-
ence EN 50176 and/or NFPA-33. Resistance to earth
ground must be less than 1 meg Ohm.
3. Flammable liquids must be contained in approved
metalic grounded containers.
1. Ensure there is a true earth ground connection available.
Connect the uid source and air hose ground to this
connection.
Interlocks Required
Interlock the solvent supply with the main supply air to
the applicator. When solvent is On, main supply air to the
applicator is Off. Interlocks are user supplied.
INSTALLATION
2. Turn off power.
3. Connect uid hose.
WARNING
!
WARNING
!
The solvent supply must be interlocked with
applicator supply air.
Both the uid source and the air hose ground must be
connected to true earth ground.
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INSTALLATION
EN

4. Connect air.
5. Trigger applicator with uid off. Look for leaks in any
connections
6. Activate uid, check for leaks with solvent ush if required.
OR...
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INSTALLATION
EN

OPERATION
WARNING
!
APPLICATOR OPERATION
1. Set uid pressure using ow regulator.
2. Disconnect the air to the applicator.
3. Activate trigger to start material stream into grounded
metal bucket or suitable area.
4. Release trigger stop material ow.
1 - Fluid Supply
2 - Flow Regulator
6.9 bar (100psig) Max
1
2
OR...
The bucket or area sprayed into must be
grounded to true earth ground.
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OPERATION
EN