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Ransburg RANSFLEX 80445 RXi Service Manual

Applicators for in-direct charge waterbased applicators
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SERVICE MANUAL
AH-15-02.1.1
FEBRUARY - 2016
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.
®
APPLICATORS
By Ransburg
FOR IN-DIRECT CHARGE
WATERBASED APPLICATORS
MODEL: 80445 RXi
Service Manual Price:
$50.00 (U.S.)

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Summary of Contents for Ransburg RANSFLEX 80445 RXi

  • Page 1 SERVICE MANUAL AH-15-02.1.1 FEBRUARY - 2016 ® APPLICATORS By Ransburg FOR IN-DIRECT CHARGE WATERBASED APPLICATORS MODEL: 80445 RXi 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.
  • Page 2 Ransflex Applicators - MANUAL CHANGES NOTE: This manual has been changed from revision AH-15-02 to revision AH-15-02.1. Reasons for this change are noted under “Manual Change Summary” on page 62 of this manual. AH-15-02.1...
  • Page 3 Ransflex Applicators - CONTENTS PAGE SAFETY: Safety Precautions ............................1 Hazards / Safegaurds ............................2 ATEX/FM REQUIREMENTS: Ransflex RXI - Solvent Base Only ........................7 INTRODUCTION: 10-13 General Description ............................10 Ransflex New Features ..........................10 Specifications 80445 Ransflex Indirect Charge Waterbase .................11 Typical Installation ............................13 INSTALLATION: 14-15...
  • Page 4 † electrostatic coating system, read and understand all Safety Section in this manual and the Ransburg of the technical and safety literature for your Ransburg safety literature therein identified. products. This manual contains information that is important for you to know and understand. This This manual MUST be read and thoroughly †...
  • Page 5 Ransflex Applicators - SAFETY HAZARD SAFEGUARDS AREA Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Spray Area Fire Hazard Fire extinguishing equipment must be present in the spray area and tested periodically. Improper or inadequate Spray areas must be kept clean to prevent the operation and maintenance...
  • Page 6 Ransflex Applicators - SAFETY HAZARD SAFEGUARDS AREA Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Explosion Hazard Spray Area Improper or inadequate Electrostatic arcing must be prevented. Safe sparking operation and maintenance distance must be maintained between the parts being procedures will cause a fire coated and the applicator.
  • Page 7 Ransflex Applicators - SAFETY HAZARD SAFEGUARDS AREA Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Spray Area / Electrical Discharge High Voltage Parts being sprayed and operators in the spray area There is a high voltage device Equipment that can induce an electrical must be properly grounded.
  • Page 8 Ransflex Applicators - SAFETY HAZARD SAFEGUARDS AREA Tells what the hazard is. Tells how to avoid the hazard. Tells where hazards may occur. Electrical Discharge Electrical Equipment Unless specifically approved for use in hazardous High voltage equipment is locations, the power supply, control cabinet, and all utilized in the process.
  • Page 9 7, 8, and 9. This product is approved for use only with non-flammable water-based materials when the materials meet the FM definition for a By Ransburg waterbased spray material*. It is the end users’ responsibility to insure the material that is sprayed meets this requirement.
  • Page 10 Ransflex Applicators - INTRODUCTION RANSFLEX RXI - SOLVENT BASE ONLY 80445 - ABCDEF Base Optional Model No. Designations (Ordering Information Only) CONFIGURATION DWG. 80513-00 REV. A Return To Contents AH-15-02.1...
  • Page 11 Ransflex Applicators - INTRODUCTION “R” (Air Cap) “S” (Fluid Nozzle) “T” (Pressure Reducer) ATOMIZATION - TABLE OF “A” DASHES “R” “S” “T” “A” Dash No. “A” Description T SERIES 1.2mm 80383-00 80239-12 74963-05 T SERIES 1.4mm 80383-00 80239-14 74963-05 T SERIES 1.8mm 80383-00 80239-18 74963-05...
  • Page 12 Ransflex Applicators - INTRODUCTION “W” 80269-45 FLUID INLET - TABLE OF “D” DASHES “D” Description “W” “D” Dash No. STD FLUID INLET TUBE 80269-45 FLUID HOSE - TABLE OF “E” DASHES “X” “E” Dash No. “E” Description NO FLUID HOSE FLUID HOSE, 10m 80303-10 FLUID HOSE, 15m...
  • Page 13 Ransflex Applicators - INTRODUCTION INTRODUCTION GENERAL DESCRIPTION RANSFLEX NEW FEATURES The Ransflex is an air atomizing applicator powered • Light weight and easy to maneuver. only by a pressurized air source. Pressurized air creates • Ergonomic handle design to reduce rotation of a turbine generator that powers a cascade.
  • Page 14 Ransflex Applicators - INTRODUCTION 80445 RANSFLEX INDIRECT CHARGE WATERBASE SPECIFICATIONS Environmental/Physical Applicator Length: 254mm (10-inches) Weight: (Without Hose) 600 grams (21.3 oz.) Hose 79727-XX Lengths (Std): 10m, 15m, 20m, and 30m Electrical Operating Voltage: 45kV DC (-) maximum Current Output: 140 microamperes maximum Paint Resistance:* Waterbase paint only with grounded source...
  • Page 15 Ransflex Applicators - INTRODUCTION Figure 1: Ransflex Indirect Charge Waterborne Electrostatic Spray Applicator 80445 RANSFLEX INDIRECT CHARGE WATERBORNE ELECTROSTATIC SPRAY APPLICATOR 80445 Description Description Exhaust Air Hose Needle/Electrode Fluid Hose Barrel Voltage On/Off Switch Handle Trigger Fan Adjustment Compensation Valve Fluid Adjustment Air Cap with Charging Electrodes / Fluid Nozzle Air Hose...
  • Page 16 Ransflex Applicators - INTRODUCTION Figure 2: Ransflex Installation for Waterbase Materials RANSFLEX INDIRECT CHARGE WATERBASE TYPICAL INSTALLATION Description Description Ransflex Fluid Supply (Grounded) Ball Valve Fluid Regulator Air Regulator with Pressure Gauge Air Hose (79727-XX) Air / Water Separator Air Hose Ground Wire Main Air Supply Line Fluid Line Return To Contents...
  • Page 17 -4°F (-20°C), CONDITIONS! the relative humidity (RH) of the air should be 5%. 2. Ransburg recommends that a fluid filter be installed GENERAL INSTALLATION at the output of the fluid supply (pressure pot, pump, circulating system, etc.).
  • Page 18 Ransflex Applicators - INSTALLATION 2. All objects inside spray area must be grounded - 2. Turn off power. reference EN 50 176 and/or NFPA-33. Resistance to earth ground must be less than 1 meg Ohm. 3. Liquids must be contained in approved metalic grounded containers.
  • Page 19 Ransflex Applicators - OPERATION OPERATION APPLICATOR OPERATION 1. Set fluid pressure using flow regulator. 6.9 bar (100psig) Max 4. Release trigger stop material flow. 1 - Fluid Supply 2 - Flow Regulator 2. Disconnect the air to the applicator. 5. Re-connect air supply. OR...
  • Page 20 Ransflex Applicators - OPERATION T-40 AIR CAP 80240-00 Static Pressure at Wall Dynamic Pressure at Wall 79727-XX Length psig psig 30 m 20 m 15 m 10 m 10. Turn on voltage and trigger applicator. Green light should be on. 11.
  • Page 21 Ransflex Applicators - OPERATION 15. Adjust compensation valve with small driver. (Horns Vertical) NOTE † The compensation valve adjustment is used to adjust fan and atomization pressure at the same time when the pressure to run the turbine is higher than the atomization fan pressure desired. FLUSHING / COLOR CHANGE PROCEDURE 1.
  • Page 22 The following charts show the nozzles and air caps available for the Ransflex. 2. Disconnect air to applicator. CAUTION † Nozzles from previous Ransburg design are not compatable with the Ransflex design. Use of these nozzles could cause equipment malfunction and possible damage.
  • Page 23 Ransflex Applicators - OPERATION 80383-00 / 80239-XX T SERIES Nozzle Part Number For Use With Air Cap P/N Color Nozzle Opening 80239-07 80383-00 Black 0.7 mm 80239-10 80383-00 Black 1.0 mm 80239-12 80383-00 1.2 mm 80239-14 80383-00 Grey 1.4 mm 80239-18 80383-00 Green...
  • Page 24 (i.e. high flash Naphtha). If there are any questions as to what solvents are † DO NOT operate a faulty applicator! best for cleaning , contact your local Ransburg distributor and/or your paint supplier. † When using cleaning solvent, standard health and safety precautions should apply.
  • Page 25 Ransflex Applicators - MAINTENANCE CAUTION CAUTION † Nozzles from previous Ransburg design † NEVER remove the fluid nozzle assembly are not compatable with the Ransflex design. while paint is in the applicator or paint may enter Use of these nozzles could cause equipment into the air passages.
  • Page 26 Ransflex Applicators - MAINTENANCE • Check that atomizer assembly is clean and undamaged. NOTE † Standard electrode is "snap back" spray wire electrode. • Straighten the applicator electrode if necessary. • Clean the fluid filter, if used. Bi-Yearly • Check air hose resistance. If resistance is greater than .5 MW the hose should be replaced.
  • Page 27 Ransflex Applicators - MAINTENANCE 2. O-ring in barrel, replace as required. 2. Clean and replace as necessary. 3. Install in reverse order. 3. Install fluid nozzle using 80353-00 wrench. Tighten till nozzle seats on Fluid Nozzle Removal O-ring and then 1/8 additional turn.
  • Page 28 Ransflex Applicators - MAINTENANCE 2. Remove fluid tube. 2. Carefully disconnect harness by pulling connector on both sides by hand and rocking it side to side to remove. 3. Pull barrel away. 3. Replace cascade as necessary. 4. Apply LSCH 0009 grease to end of cascade. Remove/Replace Cascade 1.
  • Page 29 Ransflex Applicators - MAINTENANCE Packing Removal/Replace 5. Remove all parts, clean with non-polar solvent. Inspect for any discolored areas. Replace parts as required. 1. Remove barrel from handle. 2. Use 80353 wrench to remove nut. 6. Prior to installation apply dielectric grease inside packing tube, completely full.
  • Page 30 Ransflex Applicators - MAINTENANCE Re-Install Needle Shaft Into Barrel 10. Install Bellville washers in sequence shown. 1. Install needle shaft into barrel with die-electric grease. 11. Install rear nut. Install jam nuts finger tight. 2. Tighten packing using wrench. Pull back and forth on the needle shaft till a slight amount of drag is felt.
  • Page 31 Ransflex Applicators - MAINTENANCE Rear Cover/Motor Module Repair 2. Tighten barrel screws. 1. Loosen cover screw with 3mm driver. 2. Remove fan air cartridge with 10mm wrench. 3. Re-install fluid tube. 3. Remove rear cover and cartridge with 15mm wrench. 4.
  • Page 32 Ransflex Applicators - MAINTENANCE Motor Removal 4. Remove porting block. 1. Remove light pipe. NOTE † Block must be pulled out with fingers rocking the part side to side while pulling. 2. Remove screw and retainer. NOTE † Only remove fluid valve cartridge if parts are being changed.
  • Page 33 Ransflex Applicators - MAINTENANCE Re-assembly 4. Install screw and retainer. 1. Install porting block on motor. Align screw heads into porting recess. NOTE NOTE † There is only one way to install the motor. † Only one way to position 2.
  • Page 34 Ransflex Applicators - MAINTENANCE 7. Install gasket and re-connect motor connector to 10. Tighten cover screw. handle harness connector. NOTE † This gasket should be replaced each time the rear cover is dis-assembled. Air Valve Remove/Replace 1. Remove trigger. 2. Remove rear cover assembly. 8.
  • Page 35 Ransflex Applicators - MAINTENANCE 5. Insert air valve and spring. 3. Remove bracket, gasket and o-ring. 6. Tighten packing nut till light drag is felt on the shaft while moving it back and forth. 4. Install o-ring, gasket and bracket. 7.
  • Page 36 Ransflex Applicators - MAINTENANCE 3. Remove lower fluid nut. 6. Tighten fluid nut. Gun Wrench Functions 4. Air fiting. 80353-00 1. Adjust packings. 5. Remove rear cartridge. 2. Remove nozzles For V Series For C & T Series Return To Contents AH-15-02.1...
  • Page 37 Ransflex Applicators - INTRODUCTION TROUBLESHOOTING GUIDE General Problem Possible Cause Solution ELECTRICAL On-Off lever in wrong position Ensure the On/Off lever is in the On position. No kV Low pressure Ensure 2.8 bar (40 psig) at the applicator handle with applicator triggered. No ground connection Ensure the air hose is properly grounded to the earth ground.
  • Page 38 Ransflex Applicators - PARTS IDENTIFICATION PARTS IDENTIFICATION RANSFLEX RXI - INDIRECT CHARGE WATERBASE 80445 - ABCDEF Base Optional Model No. Designations * NOTE: All nozzles available in kits of 3. ATOMIZATION - TABLE OF “A” DASHES “2” “3” / Color “A”...
  • Page 39 Ransflex Applicators - PARTS IDENTIFICATION TRIGGER - TABLE OF “C” DASHES “5” “C” Dash No. “C” Description 2 FINGER TRIGGER 80211-00 4 FINGER TRIGGER 80386-00* FLUID INLET - TABLE OF “D” DASHES “D” Dash No. “D” Description “6” STD FLUID INLET TUBE 80269-45 FLUID HOSE - TABLE OF “E”...
  • Page 40 Ransflex Applicators - PARTS IDENTIFICATION Retaining Ring 80532-00 RETAINING RING 80532-00 Description Qty. Item No. Part No. 80531-00 NUT, RETAINING LSOR0005-17 O-RING, ENCAPSULATED Return To Contents AH-15-02.1...
  • Page 41 Ransflex Applicators - PARTS IDENTIFICATION Needle Shaft Assembly 80263-45 RXI 45kV NEEDLE SHAFT Item No. Part No. Description Qty. 70430-01 ASSEMBLY ELECTRODE, HIGH WEAR 74653-00 ADAPTER, MALE 14323-00 SEAL, CHEVRON, 3/8 DIA. 14323-00-K4 SEAL, CHEVRON (KIT OF 4) 18821-00 ADAPTER-FEMALE-CHEVRON 80257-45 TUBE, PACKING 80225-45...
  • Page 42 Ransflex Applicators - PARTS IDENTIFICATION ITEMS FOR RXI (45KV) UNIT RXI 45kV BARREL Qty. Item No. Part No. Description 80524-00 ASSEMBLY, BARREL & O-RING 80263-45 ASSEMBLY, NEEDLE SHAFT 80242-00 NUT, REAR JAM 80243-00 NUT, FRONT JAM 80258-00 SPRING, FLUID RETURN 80250-45 ASSEMBLY, CASCADE RX (45 kV) Barrel and O-Ring P/N 80524-00...
  • Page 43 Ransflex Applicators - PARTS IDENTIFICATION HANDLE COMPONENTS FOR ALL MODELS HANDLE COMPONENTS Item No. Part No. Description Qty. 80375-00 INCLUDES HANDLE (80305-00) AND REAR COVER WITH MOTOR (80378-00) ASSEMBLY (ADJUSTABLE FLUID CONTROL) 80375-01 INCLUDES HANDLE (80305-01) AND REAR COVER WITH MOTOR (80378-00) ASSEMBLY (NON-ADJUSTABLE FLUID CONTROL) 80245-00 GASKET, BARREL...
  • Page 44 Ransflex Applicators - PARTS IDENTIFICATION Handle with Rear Cover with Motor 80375-00/01 HANDLE WITH REAR COVER W/MOTOR 80375-00/01 Qty. Item No. Part No. Description 80305-00 ASSEMBLY, HANDLE 80244-00 ASSEMBLY, VALVE, AIR 80533-00 SPRING, AIR VALVE 80262-00 ASSEMBLY, VALVE, ADJUSTABLE FLUID CONTROL 80262-01 ASSEMBLY, VALVE, NON-ADJUSTABLE FLUID CONTROL 80273-00...
  • Page 45 Ransflex Applicators - PARTS IDENTIFICATION Handle Assembly 80305 HANDLE ASSEMBLY 80305 Qty. Item No. Part No. Description 80305-00 ASSEMBLY, HANDLE INCLUDES ALL PARTS BELOW, MOTOR CONTROL BOARD AND HARNESSES 80274-00 SCREW, BARREL-HANDLE 80229-00 NUT, RETAINING, AIR VALVE 10051-05 CUP SEAL, SPRING LOADED Rear Cartridge Assembly 80262-00 (Adjustable Fluid Control) REAR CARTRIDGE ASSEMBLY 80262-00 Item No.
  • Page 46 Ransflex Applicators - PARTS IDENTIFICATION Rear Cartridge Assembly 80262-01 (Non-Adjustable Fluid Control) REAR CARTRIDGE ASSEMBLY 80262-01 Qty. Item No. Part No. Description 80262-01 ASSEMBLY, FLUID CARTRIDGE (NON-ADJUSTABLE) 79001-08 O-RING, SOLVENT PROOF 80273-00 Fan Air Cartridge 80273-00 FAN AIR CARTRIDGE Item No. Part No.
  • Page 47 Ransflex Applicators - PARTS IDENTIFICATION 80378-00 Rear Cover with Motor Assembly 80378-00 REAR COVER WITH MOTOR ASSEMBLY Qty. Item No. Part No. Description 80378-00 COVER, REAR ASSEMBLY (INCLUDES ALL PARTS BELOW) 80213-00 PIPE, LIGHT 80255-00 ASSEMBLY, MOTOR 79775-00 BLOCK, PORTING 7554-61 O-RING, SOLVENT RESISTANT 80275-00...
  • Page 48 Ransflex Applicators - PARTS IDENTIFICATION 80255-00 Motor Assembly 80255-00 MOTOR ASSEMBLY Description Qty. Item No. Part No. 80255-00 ASSEMBLY, MOTOR (INCLUDES ALL PARTS BELOW) 80217-00 COVER SUPPORT, MOTOR 79796-00 SCREW, MOTOR Return To Contents AH-15-02.1...
  • Page 49 Ransflex Applicators - PARTS IDENTIFICATION 80254-00 Rear Cover Assembly 80254-00 REAR COVER ASSEMBLY Qty. Item No. Part No. Description 80254-00 COVER, REAR (CONTAINS PARTS BELOW) 80274-00 M4 X .7 SHCS Return To Contents AH-15-02.1...
  • Page 50 Ransflex Applicators - PARTS IDENTIFICATION ACCESSORIES INCLUDED WITH RX OR RFX 79862-02 3mm Hex Driver 80395-00 80353-00 Gun Wrench LSCH 0009 Grease SPARE PARTS KITS Part # Description 80548-10 T Series Atomization Kit Contains (1) 80383-00 Air Cap, (2) 80239-10 (1.0 mm) Fluid Nozzle 80548-12 T Series Atomization Kit Contains (1) 80383-00 Air Cap, (2) 80239-12 (1.2 mm) Fluid Nozzle...
  • Page 51 Ransflex Applicators - PARTS IDENTIFICATION RECOMMENDED SPARE PARTS RANSFLEX RECOMMENDED SPARE PARTS (Quantities Per Applicator) Part # Description 80239-XX Nozzle, Fluid T Series (See page 42) 80239-XX-K3 Nozzle, Fluid T Series (See page 42) (Kit of 3) 80524-00 Assembly, Barrel (RXI Models) (with Front Seal) 80250-45 Cascade Assembly (RXI Models) 80245-00...
  • Page 52 EXCLUSIONS: under normal operating conditions. Normal wear items are excluded. If, in Ransburg’s opinion the warranty item in question, or other items damaged by this part was improperly THE USE OF OTHER THAN RANSBURG APPROVED installed, operated or maintained, Ransburg will assume PARTS, VOID ALL WARRANTIES.
  • Page 53 Ransflex Applicators - MANUAL CHANGES MANUAL CHANGE SUMMARY Supersedes Service Manual AH-15-02 with the following changes: 1. Add 2 new nozzels to T SERIES Table — Page 20. 2. Insert new copy for cleaning solvents with cautions and warning — Page 21. AH-15-02.1...
  • Page 54 Ransburg Manufacturing 1910 North Wayne Street Angola, Indiana 46703-9100 Telephone: 260-665-8800 Fax: 260-665-8516 Technical Service — Assistance 320 Philips Ave. Toledo, Ohio 43612-1493 Telephone (toll free): 800-233-3366 Fax: 419-470-2233 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts.