Serv. Man. LN-9902-00.3
Contents
1. LN 9902 00 3 SECTION B B Figure 9b AquaBlock 2 Assembly Parts Identification PEO d MA H F H H ret oF i 3 ARANA H a H y oo Li B ER 5 2 O SECTION A A VIEW D D 32 INCHES REF IN TOP LEFT PORT TO TOP RIGHT PORT 29 INCHES VN RIGHT CYLINDER TO TOP RIGHT PORT 12 1 2 INCHES VIEW C C 38 39 o 8 I bu E 5 e u 2 a 5 a 29 6 PLACES TO 30 35 LBS IN 4 PLACES Figure 9c AquaBlock 2 Assembly Parts Identification SIDE FRONT BACK Ransburg LN 9902 00 3 Ransburg AquaBlock 2 Parts Identification 4X 38 TORQUE TO 20 25 LBS IN TORQUE TO 15 20 LBS IN 4X Figure 9d AquaBlock 2 Assembly Parts Identification LN 9902 00 3 40 Ransburg AquaBlock 2 Parts Identification Figure 9e AquaBlock 2 Assembly Parts Identification LN 9902 00 3 41 Ransburg AquaBlock 2 Parts Identification Figure 9f AquaBlock 2 Assemb2. Figure 1 Standard System TABLE A Fitting Selection Figure 8 PR pe ESA Assembly AquaBlock 2 Metric A12140 01 Assembly AquaBlock 2 Fractional A12140 02 LN 9902 00 3 Ransburg LN 9902 00 3 NOTES AquaBlock 2 Introduction 10 AquaBlock 2 Installation 11 INSTALLATION A WARNING gt This manual MUST be read and thor oughly 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 are safely followed A WARNING gt AllAquaBlock2 installations must com ply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping gt Refer to OSHA NFPA 30 NFPA 33 and customer s insurance requirements AQUABLOCK 2 LOCATION The AquaBlock 2 cabinet is installed between the grounded coating supply and the electrostatic spray applicator s This system provides a volt age block to prevent high voltage from following the conductive path through the water based paint line connected from the spray applicator s which are athigh voltage and the grounded paint supply The unit should be installed near the spray equipment
3. A12108 00 U CUP SEAL os i s 4 EE Sch ee ely ZZ 22222 Ransburg bottoms on the shaft to a final torque of 10 15 Ibsein 1 13 1 69 Nm Reinstall the o ring into the groove in the main body Lightly lubricate both the exterior body of the seal carrier assembly and the inside diameter of the smooth bore in the female body Slide the seal carrier assembly straightintothe female body seal carrier end first until it stops on a shoulder near the open end of the part Install the o ring onto the packing retainer Apply a small amount of red adhesive 271 7969 02 to the middle threads Put the female disconnect into a vise with non markingjaws and tighten packing retainer until it stops on the body shoulder Install coiled spring into groove around the body A12106 00 ALT VIEW VISUALLY INSPECT THIS AREA TO ENSURE THAT THERE ARE NO NICKS OR DAMAGE 2103 00 SPRING RETAINER U CUP SPRING MUST FACE THIS DIRECTION sess A Figure 7 Female Disconnect 27 LN 9902 00 3 Ransburg AquaBlock 2 Maintenance Disassembly of Female Disconnect LN 9902 00 3 AquaBlock 2 Maintenance Ransburg Reassembly of Female Disconnect LN 9902 00 3 Ransburg AquaBlock 2 Maintenance Reassembly of Female Disconnect Disassembly of Male Disconnect Continued Inspect the white face seal in the groove on threaded side of the body If there is no damage do not replace
4. a a 15 AQUABLOCK 2 SYSTEM W FLOWMETER REGULATOR 16 AQUABLOCK 2 INSTALLATION CHECRLIST n nnne nnne 17 OPERATION 19 20 cg rcc MTM 19 MAINTENANCE 21 36 DERIODICMAINTENANCE a a 21 PREVENTIVE MAINTENANCE I meme aaa nn nnnn 22 23 NS A AA 23 LKITO018 06 CERAMIC CYLINDER ASSEMBLY 200 CC PARTS LIST 24 25 TOOLS TO REBUILD DISCONNECTS sita iii 26 PROCEDURE FOR REBUILDING MALE AND FEMALE AQUABLOCK 2 DISCONNECTS ee 26 31 REMOVAL AND INSTALLATION OF MALE AND FEMALE DISCONNECTS FROM AQUABLOCK 2 ASSEMBLY a 31 32 ALIGNMENT PROCEDURE FOR DISCONNECT COUPLINGS 33 TROUBLESHOOTING GUIDE court ei 35 36 Continued On Next Page LN 9902 00 3 AquaBlock 2 Contents Ransburg CONTENTS cont PAGE PARTS IDENTIFICATION 37 48 AQUABLOCK 2 ASSEMBLY PARTS IDENTIFICATION rss 37 42 A12148 XX AQUABLOCK 2 PARTS DT EE 43 44 FITTINE SELEC MON E 44 A12140 01 FITTINGS METRIC AND A12140 02 FITTINGS FRACTIONAL PARTS LIST retorno nitri 45 46 AQUABLOCK 2 RECOMMENDED SPARE PARTS ENEE 47 A12101 00 MALE DISCONNECT ASSEMBLY PARTS strains 47 A12109 00 FEMALE DISCONNECT ASSEMBLY PARTS rennes 47 ACCESSORIE
5. I WA 2 Set Screw M12 X 1 75 20mm Lg Glass Filled Nylon Bolt M8 X 1 25 50mm Lg Glass Filled Nylon 49 1212500 Shield End Block AquaBlook 22 50 A1212 00 Bolt M6 X A 12mm Lg Nylon E 51 1212000 Holder Female QuickDisconetAquaBlock2 f 4 o3 IA 00 Holder Nut Female Quick Disconnect AquaBloc 4 A12151 00 A12109 00 Quick Disconnect Female AquaBlock 2 o 43 LN 9902 00 3 E Ransburg AquaBlock 2 Parts Identification A12148 XX AQUABLOCK 2 PARTS LIST Cont Figures 9a 9b 9c 9d Ye and 9f pate 0 Ia 55 11213200 Fiing Elbow Female Quick Disconnect AquaBiock 2 2 56 A12134 00 Fitting Y 120 Female Quick Disconnect_____________ 2 5 7900101 O Ring Solvent Proof l C C 4 58 7900114 O Ring Solvent Proof L 4 60 LKITO018 06 220 Ceramic Coated Cylinder Assembly Kit No Fittings Lock Washer 1 4 External Tooth 68 70539 00 Grounding Assembly Not Shown 69 TableA A Kit Fittings and Tubing AquaBlock2 Fitting Elbow 10mm T X 1 4 NPTM Fitting Elbow 6mm T X 1 8 NPTM Fitting Tee 6mm T X 1 8 NPTM 80 1415709 Fitting Elbow 8mm T x 1 8 NPTM Tubing Nylon 6mm Yellow 89 A12147 01 Tubing Nylon 6mm Natural Tubing PFA 8mm 90 LSMP0007 00 Tub
6. While holding the part with the threaded nipple tight against the plastic block insert the female disconnect thread ontothe nipple by hand Itmay be helpful to use the socket only with no ratchet attached Tighten until the disconnect gets close to meeting the plastic block It is best to make 1 4 or less turns at a time when tightening At this time insert a 030 0 76mm feeler gage or pin between the metal flange of the disconnect and the plastic block Tighten disconnect until a slight drag can be felt on the feeler or pin gage Make sure nipple part is pushed up against the plastic block when checking the gap Add 6 8 turns of new tape Remove all old tape carefully Removal of Disconnects LN 9902 00 3 32 AquaBlock 2 Maintenance 33 ALIGNMENT PROCEDURE FOR DISCONNECT COUPLINGS Start by loosening the six 6 plastic hex screws on the block that holds the female disconnects Loosen them only enough to allow unit to move slightly Retract jack screws on the same plastic block with a 6mm long shank hex key or T type wrench Unit should be free to float at this point Using your hand push the male disconnect block assembly to engage fully into the female discon nects While holding the connection in place tighten the four corner hex head screws of the female block assembly Tighten lightly with a 72 end wrench Tighten the remaining four 4 screws equally as light Allow the disconnects to sepa
7. Figure 2 AquaBlock 2 Pneumatic and Fluid Schematic AquaBlock 2 Installation 4 V WOW 54 001 WAOWIXVW Sd 001 S ISd 06 3018431 4 1 OU I3INI 4 AIddNs el SOVITOA HOH 13 Ransburg AquaBlock 2 Intstallation v FLUID OUT TO APPLICATOR S es el gt 28 a ub la Li 20 gt E O a 12 Dr 83 Li TS a O oo cx E x e E Y E ES A J En Figure 3 AquaBlock 2 Electrical Schematic LN 9902 00 3 14 Ransburg AquaBlock 2 Installation H L JOYLNOD Q33dS YOLOW I ei Been TT Meola 3oorgendy e Je LN 9902 00 3 Figure 4 AquaBlock 2 System W Gear Pump La 1 d be To C MOOT1M31NI 30 110 HO INdNI
8. 48 WARRANTY POLICIES 49 EMTEDIWARBA Satanas ade iia abit 49 LN 9902 00 3 Ransburg LN 9902 00 3 AquaBlock 2 Safety SAFETY SAFETY PRECAUTIONS Before operating maintaining or servicing any Ransburg electrostatic coating system read and understand all of the technical and safety literature for your Ransburg products This manual contains information that is important for you to know and understand This information relates to USER SAFETY and PREVENTING EQUIPMENT PROB LEMS 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 avoidasituation 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 drawings and appropriate Ransburg equipment manuals to reconcile such differences Careful study and continued use of this manual will provide a better understanding of the equipment and proc
9. NIV Y3sn AG Gdl dddns IN3AdInO3 SSLVOICNI GNNOYS NOYA NOLLVIOSI ONININDSY LNAWNdINODA SALVOIGNI i pas ui 15 AquaBlock 2 Intstallation 10 HOIH Om 2 LONd 401 IA933 OI IVNOIS S3I3AMO T4 lldO 83814 43sn Ag daliddNS IN3AdinO3 SILVOIONI GNNOYD NOT NOILVIOS ONISINOJY IN3AdInO3 S31VOIGNI Ransburg 00e enoy 5 y LT T 590 IJ31NI 39VLIOA LAdNI HIY NIVA Figure 5 AquaBlock 2 System W Flowmeter Regulator 16 LN 9902 00 3 AquaBlock 2 Installation Ransburg AquaBlock 2 Installation Checklist All users must carefully read and understand the Safety Precautions and all instructions before using the AquaBlock 2 system Installation must comply with appropriate local state and national codes governing ventilation fire protection operation maintenance and housekeeping Refer to OSHA NFPA 30 NFPA 33 and the customer s insurance requirements All coating materials solvents etc used in the AquaBlock 2 system must have a flash point of equal to or above 100 F Filtration is required for the paint supply as well as any water or solvent supp
10. To replace pry out of groove Do not damage threads or seating surfaces Using a snap ring pliers remove snap ring holding seat assembly into the body Remove piston assembly spring and spring retainer from the threaded end Thoroughly clean all parts and make sure they are dry before assembling Inspect the male body front face and the interior seating face behind the front face If any damage is observed the body needs to be replaced Inspect the rubber of the piston assembly Any pits scratches tears replace with new Insert piston into the body followed by the spring and spring retainer The small end of the retainer goes into the spring Reinstall the snap ring Make sure it is fully into the groove A12100 SPRING CLIP A12098 00 SPRING RETAINER A12099 00 SPRING A11392 00 PISTON ASSEMBLY 79001 50 A12097 00 BODY INSPECT FOR PITS SCRATCHES AND TEARS VISUALLY INSPECT THIS AREA TO ENSURE THAT THERE ARE NO NICKS OR DAMAGE Figure 8 Male Disconnect LN 9902 00 3 30 AquaBlock 2 Maintenance Ransburg Disassembly and Reassembly of REMOVAL AND ce INSTALLATION OF MALE AND FEMALE DISCONNECTS FROM AQUABLOCK 2 ASSEMBLY Male Disconnect Remove the white plastic shields surrounding the male disconnects Male disconnects are located on the center sliding plastic block Using a 30mm 1 316 socket or wrench unscrew disconnects Examine the front face metal and rubber pa
11. maintained Ransburg will assume no respon sibility for repair or replacement of the item or items The purchaser therefore will assume all responsibility for any cost of repair or replacement and service related costs if applicable LN 9902 00 3 Ransburg MANUAL CHANGE SUMMARY This manual was published to supercede Service Manual LN 9902 00 2 AquaBlock 2 to make the following changes 1 Change logo LN 9902 00 3 Service Manual Price 30 00 U S Manufacturing 1910 North Wayne Street Angola Indiana 46703 9100 Telephone 260 665 8800 Fax 260 665 8516 www ransburg com Technical Service Assistance Telephone 800 233 3366 Fax 419 470 2071 Technical Support Representative will direct you to the appropriate telephone number for ordering Spare Parts Form No LN 9902 00 3 O 2013 Ransburg All rights reserved ISO 9001 Litho in U S A Models and specifications subject to change without notice Quality Systems 02 13
12. 9902 00 3 Ransburg AquaBlock 2 Maintenance TROUBLESHOOTING GUIDE Cont General Problem Possible Causes Corrective Action 1 Faulty 4 way pneumatic 1 Replace 4 way pneumatic valve valve 2 Cylinder not reaching end of 2 Replace or repair cylinder stroke 3 Door safety switch not fully 3 Close door tight replace switch engaged or faulty 1 Low air pressure 1 Ensure that air pressure is set to 90 psi 5 psi LN 9902 00 3 36 AquaBlock 2 Parts Identification Ransburg PARTS IDENTIFICATION yo M SCHEMATIC LABEL OF THIS KIT IS INSTALLED ON THE INSIDE OF THE DOOR AE WP 2 AquaBlockZ Nu Gs A M h Rensburg DOOR LATCH ASSEMBLY E Figure 9a AquaBlock 2 Assembly Parts Identification 37 LN 9902 00 3 Ransburg 000000 BOTTOM LEFT AND RIGHT PORTS 17 INCHES EACH TOP LEFT AND RIGHT PORTS 16 1 2 INCHES AquaBlock 2 Parts Identification FLUID INLET 18 INCHES y
13. ITFTC T005 Fiting Stainless Steel Bulkhead mm or BLT Tf Tubing Nylon 0mm or 3 8 Natural Not Shown Tubing Nylon 8mm or 5 18 Green Not Shown 45 0 ubing Nylon 8mm or 5 Yellow Not Shown Tubing Nylon 6mm or 1 4 Keen Not Shown s TP I 78326 00 A10809 02 Tubing Nylon 6mm or 1 4 Yellow Not Shown 9 5 35 pe AT2147 01 THSAT Tubing Nylon 6mm or 1 4 Natural Not Shown 24 75 CEE 10 5 1 25 7 5 ES A10841 01 76698 04 Tubing PFA 8mm or 3 8 Not Shown 19 33 33 13 13 LN 9902 00 3 46 AquaBlock 2 Parts Identification Ransburg AQUABLOCK 2 RECOMMENDED SPARE PARTS Q__A I TSOR0007 03 O Ring Solvent Resistant z 7900137 O Rig SoventPro A 79001 01 O Ring Solvent Proof 4 7900134 O ig SoventProf A A12101 00 MALE DISCONNECT ASSEMBLY PARTS SSS A12097 00 00 25 EE A12109 00 FEMALE DISCONNECT ASSEMBLY PARTS 7900149 O RngSoventProf 94 mu 2222 E m ri Re I III SA ee ee 47 LN 9902 00 3 Ransburg ACCESSORIES Thread Tape Petroleum Jelly Thread Sealant White Paste 7969 10 Adhesive 271 Red 7969 02 Adhesive 243 Blue 7969 03 LN 9902 00 3 AquaBlock 2 Parts Identification 48 AquaBlock 2 Warranty Policies 49 Ransburg WARRANTY
14. and operated in accordance with NFPA 33 NEC and OSHA requirements AquaBlock 2 Safety AREA Tells where hazards may occur General Use and Maintenance Electrical Equipment Explosion Hazard Incompatible Materials HAZARD Tells what the hazard is Improper operation or mainte nance may create a hazard Personnel must be properly trained in the use of this equip ment High voltage equipment is uti lized Arcing in areas of flam mable or combustible mater ials may occur Personnel are exposed to high voltage during operation and maintenance Protection against inadvertent arcing that may cause a fire or explosion is lost if safety circuits are disabled during operation Frequent power supply shut down indicates a problem in the system which requires correction An electrical arc can ignite coat ing materials and cause a fire or explosion Halogenated hydrocarbon sol vents for example methylene chloride and 1 1 1 Trichloro ethane are not chemically com patible with the aluminum that might be used in many system components The chemical re action caused by these solventg reacting with aluminum can be come violent and lead to an equipment explosion Ransburg SAFEGUARDS Tells how to avoid the hazard Personnel must be given training in accordance with the requirements of NFPA 33 Instructions and safety precautions must be read and understood prior to using this equipment Comply
15. for wear or damage and replace as re quired General Overall cleanliness of the AquaBlock 2 is key to maintaining voltage blocking capabilities and help ing to ensure trouble free operation The internal and external surfaces of the AquaBlock 2 should be cleaned periodically for efficient operation 1 Coating material should be cleaned from the inside of the AquaBlock 2 enclosure immediate ly Conductive coatings left on surfaces effect system operation and may lead to poor system performance 2 Ensure proper operation of interlocks High Voltage AquaBlock 2 pneumatic circuit etc 4 Way Shuttle Assembly The main components of the 4 Way Shuttle As sembly include the rodless cylinder and the four 4 pairs of quick disconnects The rodless cylinder is not field repairable Care should be taken to ensure their cleanliness and proper use and they should provide a long service life Should service or repair be required the rodless cylinder should be returned to Ransburg in Angola IN The quick disconnects are serviceable See Procedure for Rebuilding Male and Female AquaBlock 2 Disconnects in the Maintenance section 1 Coating material should be cleaned from the LN 9902 00 3 AquaBlock 2 Maintenance face of the rodless cylinder immediately Care should be taken to ensure that any cleaning sol vents used do not enter any of the openings of the rodless cylinder 2 Ensure proper alignment of quick disconne
16. mounting blocks and a pneumatic actuator The AquaBlock 2 has four 4 Female Quick Disconnects that are located on two 2 stationary End Blocks One End Block is mounted on the left side of the shuttle assembly and one is mounted on the right side Four 4 Male Quick Disconnects are located on a moving Center Block with two on each side The movement of the Center Block Male Quick Dis connects is controlled by the pneumatic actuator As the AquaBlock 2 operates the Center Block is shuttled back and forth to create a connection to alternating sides of the cylinder and the paint inlet and outlet The 4 way shuttle assembly receives grounded paint from the paint supply system and directs it to one end of the cylinder assembly The paint being forced into the cylinder forces paint out of the other side using incoming paint pressure The paint being forced out of the cylinder assem bly then flows through another port of the 4 way shuttle assembly and out to the atomizer When the filling side of the cylinder is full a pneumatic signal is sentto the actuator that moves the 4 way shuttle The flow of paint in the 4 way shuttle is now switched and the emptied side ofthe cylinder is now filling with paint from the grounded paint supply The full side of the cylinder is now con nected to the atomizer Actuator The pneumatic actuator is a part of the 4 way shuttle assembly It is located in the back portion of the assembly and is shiel
17. nut Remove stem through the front Remove the piston packing black rubber piece from the seal carrier and re place with a new part Remove the white spring energized u cup seal on the exterior of the seal carrier body Do not damage the sealing surface that it is located on Replace the seal with a new part 26 AquaBlock 2 Maintenance Thoroughly clean all parts and make sure they are dry before assembling Install the new piston packing black rubber piece into the front opening large end first Make sure the top is even and a little above the metal body Reassemble the white spring energized seal onto the seal carrier with the spring side facing to the open bore end Start at one spot and using both thumbs push evenly on both sides until itsnaps on Any damage to this seal during the assembly process will result in a leak Insert the stem from the rubber side end Slide the spring over the stem and compress the spring enough to insert an awl through the stem hole Compressing the spring will aid when installing the hex nut Install the spring retainer onto the stem with the legs toward the seal carrier side Apply a small amount of blue adhesive 243 7969 03 to the first one or two threads only of the hex nut and install until it A12104 00 PACKING RETAINER APPLY RED THREAD LOCK TO THESE THREADS VISUALLY INSPECT THIS AREA TO ENSURE THAT THERE ARE NO NICKS OR DAMAGE A11391 00 PISTON PACKING A12105 00 STEM
18. the system during the switching operation This location requires that the pump and any other conductive objects attached to the pump be isolated from ground Figures 4 and 5 illustrate basic examples of typical installations for the AquaBlock 2 system Figure 4 shows a typical system with an isolated gear pump flow control system and Figure 5 shows a typical system with an isolated flowmeter and fluid regulator flow control system 12 Ransburg LN 9902 00 3 01 4 NOLISOd 143 s uolvoridev NOILISOd LHOld OL 1no ama 81 160 ama SS3100 SS 10093 CE e E ES ol Ja y ol Ja A lt Y va 69 99 5 _ 69 09 4 75 E CJ Une 1431 1 8691 137 ON dol INIL WOLLOS ONIL dot ONIS WOLLOS 8 1 F i Y ut y v6 Was y ve 4 I 8 Yir y I Y a Tire
19. with appropriate local state and national codes governing ventilation fire protection opera tion maintenance and housekeeping Reference OSHA NFPA 33 and your insurance company require ments The power supply optional remote control cabinet and all other electrical equipment must be located outside Class or Il Division 1 and 2 hazardous areas Refer to NFPA 33 Turn the power supply OFF before working on the equipment Test only in areas free of flammable or combustible material Testing may require high voltage to be on but only as instructed Production should never be done with the safety circuits disabled Before turning the high voltage on make sure no objects are within the sparking distance 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 equip ment 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 material supplier Any other type of solvent may be used with aluminum equipment LN 9902 00 3 Ransburg AREA HAZARD Tells where hazards Tells what the hazard is may occur Toxic Substances Certain material may be harm ful if inhaled or if there is con tact with the skin Intended Use Using coating mater
20. 0018 06 200CC CERAMIC CYLINDER ASSEMBLY PARTS LIST Figure 6 LAQU0024 00 Center Section Machined Cylinder Reservoir LAQU0013 00 Plate Machined Cylinder Support LSFA0017 00 SFHC Screw 1 4 20 x 1 2 Lg 77725 02 Cylinder Reservoir Assembly Paint LAQU0012 02 Connecting Rod Machined Cylinder Reservoir ion ined 6 ined 8 e 25 LN 9902 00 3 Ransburg AquaBlock 2 Maintenance TOOLS REQUIRED TO REBUILD DISCONNECTS 30mm Socket 1 3 16 7mm Socket 9 32 Awl or Rod 1 5mm Diameter 1 16 Snap Ring Pliers Internal Type PROCEDURE FOR REBUILDING MALE amp FEMALE AQUABLOCK 2 DISCONNECTS Female Disconnect After removal of the disconnect from the Aqua block assembly carefully remove the coiled spring around the body Inspect the spring for any damage If there are any flat spots or kinks to it replace the part Hold the small end of disconnect in a vise with non marking jaws Using a 30mm 1 3 16 wrench or socket unscrew the packing retainer from the main body Using your finger or a non metallic device push the assembled stem LN 9902 00 3 parts out of the main body from the large end Remove the o ring from the groove near the large end of the body Disassemble the seal carrier assembly as follows Using an awl or other similar devise insert it into the hole located in the stem through the spring as a holding devise Use a 7mm 9 32 nut driver or socket to unscrew the hex
21. 4 7 8 and 9 onto each end Tighten the piston assemblies securely by hand then tighten each jam nut 6 6 Slide one 1 of the piston assemblies about half way into one of the reservoirs 10 by pushing squarely on the opposite piston assembly Care fully thread the reservoir onto the center section and tighten securely using the RPM 419 wrench Push the exposed piston unit until it bottoms against the center section Carefully thread the remaining reservoir onto the center section and tighten securely with the wrench 7 Install the cylinder reservoir assembly using the two 2 nylon mounting screws 29 provided with the unit 8 Connect the pneumatic end of stroke signal lines to the fittings in the cylinder reservoir center section 9 Connect the fluid tubes at each end of the cylinder reservoir Tighten the tube fitting nuts securely and slide the polyurethane tubing over each fitting 10 Turn on the main air supply 11 The unit is now ready to resume operation 12 Follow Start Up Procedures and check for leaks NOTE gt f fluid flow cannot be established through the system then the cylinder res ervoirassembly may be out of phase with the shuttle block assembly Interchange the pneumatic end of stroke signal lines at the cylinder reservoir center section to obtain flow LN 9902 00 3 AquaBlock 2 Maintenance Ransburg LN 9902 00 3 AquaBlock 2 Maintenance Ransburg LKIT
22. 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 workmanship or material provided that the equipment has been used and maintained in accordance with Rans burg s written safety and operating instructions and has been used under normal operating con ditions 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 example guns power supplies control units etc is one 1 year from date of purchase WRAPPING THE APPLICATOR IN PLASTIC WILL VOID THIS WARRANTY RANSBURG S ONLY OBLIGATION UNDER THIS WARRANTY IS TO REPLACE PARTS THAT HAVE FAILED BECAUSE OF FAULTY WORKMANSHIP OR MATERIALS THEREARE NOIMPLIED 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 GOODWILLOR 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 otheritems damaged by this part was improperly installed operated or
23. Ransburg SERVICE MANUAL LN 9902 00 3 Replaces LN 9902 00 2 February 2013 AQUABLOCKZ AgquaBlockZ Ransburg O MODEL A12148 XX IMPORTANT Before using this equipment carefully read SAFETY PRECAUTIONS starting on page 1 and all instructions in this manual Keep this Service Manual for future reference Service Manual Price 30 00 U S Ransburg NOTE This service manual has been superceded from service manual number LN 9902 00 2 to service manual number LN 9902 00 3 Reasons for this change are noted under Manual Change Summary inside the back cover of this manual LN 9902 00 3 Ransburg AquaBlock 2 Contents CONTENTS PAGE SAFETY 1 4 SAFETYPRECAUTIONS usas 1 HAZARDS SAFEGUARDS a nana nana 55 2 4 INTRODUCTION 5 10 ET 5 6 SPEGCIEICATIONS 6 DESCRIPTION Siracusa rata EE 7 8 AQUABLOCK 2 MODEL IDENTIFICATION scort 9 STANDARD SYSTEM EE 9 INSTALLATION 11 18 AQUABLOCK ECH ee NN el EE 11 LAY CSTE y o RENE 11 PNEUMATIC CONNEGCTIONS 1n ti unte pnt et SES 11 PAINT SUPP IV dX 11 12 AQUABLOCK 2 PNEUMATIC AND FLUID SCHEMATIC nnne 13 AQUABLOCK 2 ELECTRICAL SCHEMATI CC ooncccincncnnccnnnonononcnnnancnnoncnnnncnonancnnnncnnnncnononacinaninns 14 AQUABLOCK 2 SYSTEM W GEAR PUNP
24. cts at each end of the shuttle stroke Jack screws are provided for fine adjustment when required See Adjustment Procedure inthe Maintenance section 3 Inspect inlet and outlet tubing for abrasion or wear Cylinder Assembly The cylinder reservoir assembly 60 has a double piston The pistons are fed by the 4 way shuttle assembly This sub assembly can be easily re placed for repair or preventive maintenance The cylinder reservoir assembly should be repaired or replaced approximately every 6 months This frequency may be increased in applications using abrasive coatings Removal 1 Thoroughly flush the coating material from the system and relieve the fluid pressure 2 Disconnect the fluid tubes at each end of the cylinder reservoir 3 Disconnectthe pneumatic end of stroke signal lines from the cylinder reservoir center section 4 Loosen and remove the two 2 mounting screws 29 and remove the assembly Disassembly Refer to Figure 6 1 Drain as much purge material as possible from each reservoir 2 Place the assembly s mounting plate 2 on a flat surface and unscrew each reservoir 10 using the RPM 419 wrench assembly 3 Loosen both jam nuts 6 at either end of the connecting rod 5 and unscrew each piston as sembly 22 AquaBlock 2 Maintenance 23 NOTE During removal of the reservoirs one of the pistons may unscrew itself from the connecting rod If this occurs install th
25. ded from high voltage by aseries of shields covers and mounting blocks When a pneumatic signal is received from the 4 way valve of the pneumatic control assembly the actuator moves the center block from one end of the shuttle assembly to the other Once the 4 way shuttle assembly is switched the air signal is maintained to overcome the spring force of the quick disconnects and hold the connection Ransburg Pneumatic Control Assembly This assembly includes a 4 way pneumatic valve which controls the operation of the actuator in response to pneumatic signals received from the end of stroke sensors in the cylinder assembly There are specially sized orifices built in to the 90 degree cross fitting at the inlet of the 4 way pneumatic valve which are connected to each of the pilots These restricted orifices supply a low volume of air to the pneumatic sensor circuit in the cylinder assembly The 4 way valve is normally maintained in an open position to one of the specified outlet ports When it receives an end of stroke signal from the cylinder assembly it switches to the other port The valve supplies air to move the actuator and the 4 way shuttle assembly to the opposite side Cylinder The cylinder is a double ended piston reservoir with a port located at each end The pistons are moved by fluid pressure entering one end of the cylinder from the paint supply system while it is evacuated from the other end and fed to the applicator
26. e connecting rod and pull the piston from the reservoir If piston cannot be pulled out place the reservoir on a flat surface Apply air pressure as required to the fluid port until piston becomes free DO NOT USE EXCESSIVE PRESSURE 4 Thepiston 4 assembly consists of the piston piston seal 9 seal retaining plate 7 and o ring 8 Remove the seal retaining plates by pulling each assembly apart with a twisting motion 5 Remove the piston seals and discard them 6 Remove the o rings located in the seal retaining plate and inspect them for swelling or damage If the o rings have swollen they should be replaced RE ASSEMBLY See Figures 6 7b and 7c 1 Thoroughly clean all traces of coating material dirt etc from all components gt Cleanliness of the cylinder reservoir assembly is essential to its operation as a voltage blocking device After the compo nents have been thoroughly cleaned they must be wiped down witha non polar solvent such as high flash Naphtha to reduce any amount of conductive residue 2 Inspect the ceramic sleeves inside each res ervoir 10 for excessive wear If the sleeves contain deep scoring then the reservoir should be replaced 3 Install piston seals 9 o ring end first onto each piston 4 Ransburg 4 Install o rings 8 into grooves on each seal retaining plates 7 5 Install connecting rod 5 through the center section 1 and thread the piston assemblies
27. e paint to flow through the AquaBlock for 3 4 cycles of the 4 way Shuttle Assembly and turn off the trigger valve s Adjust the paint supply pressure to the system to between 20 and 100 psi 2 Thesystemisnowready for operation and high voltage may be turned on at the power supply LN 9902 00 3 Ransburg LN 9902 00 3 NOTES AquaBlock 2 Operation 20 AquaBlock 2 Maintenance 21 MAINTENANCE A WARNING gt Prior to performing any maintenance on the AquaBlock 2 shut off relieve and lock out all pressure and power sources including com pressed air flush material and coating supply systems and high voltage power supplies PERIODIC MAINTENANCE Shift Daily 1 Without high voltage applied to the applica tor s check outside and inside of the AquaBlock cabinet for any fluid leaks and correct as needed 2 Flush the AquaBlock 2 fluid lines cylinder etc with appropriate flushing solvents using normal color change procedures NOTE gt The steady state current of the Aqua Block 2 refers to the current read ing when the 4 way shuttle is in one of the two end positions The switching current refers to the AquaBlock 2 current when the 4 way shuttle is switching 3 Open the AquaBlock 2 cabinet door and en sure free movement of 4 way Shuttle by pushing back and forth by hand 4 Remove the eight 8 Quick Disconnect Shields by turning counter clockwise 5 Clean Quick Disconnect Shields u
28. e AquaBlock 2 cabinet contains the 4 way shuttle assembly the cylinder and pneumatic sensing switching valves Be cause itis pneumatically controlled the AquaBlock 2 can be located inside or outside of hazardous areas The paint enters one port of the 4 way shuttle as sembly and is connected alternately to one of two outlets at each end of the cylinder The cylinder is a double ended piston assembly having a 220cc capacity The physical disconnect of the 4 way shuttle assembly in conjunction with the cylinder provides electrical isolation between the paint connections The 4 way shuttle is moved by a pneumatic actuator which is actuated by the end of stroke sensors built in to the cylinder assembly Thus the system operates with minimal interrup tion or delay providing a smooth continuous flow of paint to the spray applicator s The AquaBlock 2 system is a modular design which can be integrated into any existing paint feed system handle single or multiple automatic applicators and requires little maintenance Color change through the AquaBlock 2 can be ac comp lished in as little as 60 seconds depending on the system configuration LN 9902 00 3 Ransburg NOTE Most power supplies manufactured by Ransburg can be used with the AquaBlock 2 System However in existing installa tions where older models are in use the high voltage system should be pre tested using the recommended test procedure to determine if a newe
29. e tap water Deionized water is acceptable NOTE Fluid pressure both paint and water supplies at the paintinlet must not exceed 100 psi 1 Connect the paint inlet line to a supply of flushing solvent Disconnect the outlet paint line after the exit of the cabinet and turn on the water solvent mixture supply Collect the water solvent mixture in a grounded container for approximately sixty seconds to make sure any contaminates in the system are flushed out Turn off the water solvent mixture supply and reconnect the paint line Turn on the water solvent mixture supply and open the trigger valve s to the applicator s Allow water solvent mixture to flow through the AquaBlock 2 for 3 4 cycles of the 4 way Shuttle Assembly and turn off the trigger valve s Ransburg NOTE The paint supply pressure to the AquaBlock 2 must be above 20 psi to establish proper flow through the system and less than 100 psi to prevent leakage or damage The supply pressure should be minimized to a suitable pressure to achieve required flow 2 Check for leaks around all connections inside and outside the system 3 Turn the water solvent mixture supply off and relieve the system of pressure Disconnect the paint line from the water solvent mixture supply and connect the paint supply line to the system Charging the System With Paint 1 Turnthe paintsupply on to the system and open the trigger valve s to the applicator s Allow th
30. ess resulting in more efficient operation longer trouble free service and faster easier trou bleshooting If you do not have the manuals and safety literature for your Ransburg system contact your local Ransburg representative or Ransburg Ransburg A WARNING gt The user MUST read and be familiar withthe Safety Section inthis manual and the Ransburg safety literature therein identified gt This manual MUST be reaed and thor oughly 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 andordinances as well as NFPA 33 SAFETY STANDARD prior to installing operating and or servicing this equipment A WARNING gt The hazards shown on the following page may occur during the normal use of this equipment Please read the hazard chart beginning on page 2 LN 9902 00 3 Ransburg AREA Tells where hazards may occur Spray Area Ch LN 9902 00 3 d HAZARD Tells what the hazard is Fire Hazard Improper or inadequate op er ation and maintenance pro cedures 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 shut down ind
31. h is electrically conductive This means that in an electrostatic spray system the supply of water based coatings must be isolated from ground to prevent the high voltage from shorting out through the conductive water based coating For many years isolated paint supply systems have been used in electrostatic spray systems when highly conductive coatings were applied This was a necessary condition if you were using electrostatics and conductive coatings As the use of water based coatings increased the need for other methods to avoid the use of iso lated coating supplies became obvious Isolated coating supplies require a lot of floor space the use of protective fencing around the isolation area and in many cases long delays in production are experienced to accomplish color change To respond to this need Ransburg has devel oped the AquaBlock 2 which is a high vol tage blocking device used to prevent the high voltage from following the conductive path from the spray applicator through the paint line to the grounded water based coating supply The AquaBlock 2 is inserted between the grounded paint supply line entering the spray booth and the spray applica tor s One AquaBlock 2 can be used for one or more automatic spray applicators There is a Ransburg pressure drop across the system depending on the viscosity and volume of paint going through the system The voltage block system is comprised of the AquaBlock 2 cabinet Th
32. ials and or cleaning and flushing solvents which fave flash points below 100 F 37 8 C may cause a fire hazard LN 9902 00 3 AquaBlock 2 Safety SAFEGUARDS Tells how to avoid the hazard Follow the requirements of the Material Safety Data Sheet supplied by coating material manufacturer Adequate exhaust must be provided to keep the air free of accumulations of toxic materials Use a mask or respirator whenever there is a chance of inhaling sprayed materials The mask must be compatible with the material being sprayed and its concentration Equipment must be as prescribed by an industrial hygienist or safety expert and be NIOSH approved This system is intended for use with waterborne coating formulations only AquaBlock 2 Introduction INTRODUCTION FEATURES Over the past several years the finishing industry has experienced increasing pressure to meet the requirements of environmental legislation aimed at reducing the amount of air pollution being gen erated by the painting process This has brought about increased use of conforming coatings such as water based paints which contain less solvent Another obvious answer to reducing the use of solvents is to reduce the amount of coating being applied This can be accomplished by the use of electrostatic applicators Therefore it appeared logical to combine these two solutions to achieve the best of both worlds However water based coatings contain water whic
33. icates a prob lem in the system requiring correc tion AquaBlock 2 Safety SAFEGUARDS Tells how to avoid the hazard Fire extinguishing equipment must be present in the spray area and tested periodically Spray areas must be kept clean to prevent the accu mulation of combustible residues Smoking must never be allowed in the spray area The high voltage supplied to the atomizer must be turned off prior to cleaning flushing or maintenance When using solvents for cleaning Those used for equipment flushing should have flash points equal to or higher than those of the coating material Those 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 and local codes In ad dition ventilation must be maintained during cleaning operations using flammable or combustible solvents Electrostatic arcing must be prevented 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 equip ment modifications may cause fire or injury If used the key switch bypass is intended for use only during set up operations Production should never be done with safety interlocks disabled Never use equipment intended for use in waterborne installations to spray solvent based materials The paint process and equipment should be set up
34. ing Tygon 3 4 ID X 1 OD Both tubes must be equal in length Both tubes must be equal in length TABLE A Fitting Selection Figure 10 Description Assembly AquaBlock 2 Metric A12140 01 Assembly AquaBlock 2 Fractional A12140 02 LN 9902 00 3 A AY AININ A 1 16 16 44 5 44 5 24 75 111 1 0 5 4 44 Ransburg AquaBlock 2 Parts Identification Figure 10 A12140 01 Fittings Metric and A12140 02 Fittings Fractional LN 9902 00 3 45 Ransburg AquaBlock 2 Parts Identification A12140 01 FITTINGS METRIC AND A12140 02 FITTINGS FRACTIONAL RORIS SE E 2d A12150 00 A12163 00 Fitting Inline Y 10mm or 3 8 T A12150 00 A12164 00 Fitting Bulkhead 10mm or 3 8 T A12152 00 A12165 00 Fitting Elbow 10mm or 3 8 T X 1 4 NPTM 4 A12153 00 A12153 00 Fitting Universal Restricted Outlet 8mm or 5 16 T X 1 4 NPTM A12154 00 A12167 00 Fitting Elbow 6mm or 1 4 T X 1 8 NPTM A12155 00 A12168 00 Fitting Reducer Elbow 10mm or 3 8 T X 6mm or 1 4 T 7 1215500 1216900 Fitting Bulkhead Gram or T ES E 8 A1215700 AT2170 00 Fitting Tee emmo 1 Co AS A200 Fiting Tee 6mmor TE TXIEN PI ESUR E A EE 09 1918709 iting Elbow 8mm or STS TX TE NPTM Fig Nylon Elbow 6mm ot TA TX TR NET DI 3 Fitting Nylon 8mm or 5 16 T X 3 8 AN 8 L4 M23900
35. ing through the AquaBlock 2 from the electrostatic applicator This current measure mentprovides usefulinformation as to the level of contamination inside the quick disconnectshields contamination inside the cabinet and abnormal system operation such as quick disconnect or fluid seal leakage etc Current Meter The scale on the microampere meter is divided into three zones refer to Current Meter chart Each time the 4 way shuttle assembly switches there is a possibility that the current meter will show a current reading momentarily Ifthe needle on the meter returns slowly to the steady state current or stays high this could be an indication of a problem situation that requires immediate attention and potential system damage LN 9902 00 3 8 AquaBlock 2 Introduction Ransburg AQUABLOCK 2 MODEL IDENTIFICATION When ordering use A12148 AA as indicated by Table A see Table A in the Parts Identification section Two digits must follow the basic part number for example A12148 XX Basic Part Number TableA Fitting Selection Model number and serial number are located on the face of the rear plate assembly bil oo B Ce Hi H BHAA
36. int pressure 2 Ensure that paint supply pressure is above 20 psi 3 Contamination in cylinder 3 Replace or repair cylinder 4 Low air pressure 4 Ensure that air pressure is set to 90 psi 5 psi Low Paint Flow 1 Low pressure in the paint 1 Increase paint supply pressure above 20 psi supply system 2 Contamination in cylinder 2 Replace quick disconnect s Quick Disconnect 1 Over pressure 1 Decrease paint supply pressure below 120 psi Leakage 2 Worn or damaged seal s 2 Replace quick disconnect s 3 Quick disconnect misaligned 3 Align quick disconnect s 4 Drymaterialbetweensealand 4 Repair or replace disconnect s seat Cylinder Leakage 1 Worn or damaged piston 1 Replace or repair cylinder seal s High Current 1 High voltage shields missing 1 Install high voltage shields ensuring that they are fully installed 2 Contaminated component 2 Clean all surfaces with a strong solvent and surfaces inside AquaBlock rewipe surface with a non polar solvent 2 cabinet 3 Cylinder leakage 3 Replace or repair cylinder 4 Pin hole in tubing and or 4 Replace pin holed tube and or fitting and fitting clean all contaminated surface 5 Fluid leaking from tubing and or fittings 5 Tighten or replace fitting and clean all contaminated surface 6 Polyurethane tube shields missing from tubing 6 Install polyurethane tube shields 7 Contaminated quick 7 Clean shields or replace disconnect shields 35 LN
37. ly Parts Identification LN 9902 00 3 42 AquaBlock 2 Parts Identification Ransburg A12148 XX AQUABLOCK 2 PARTS LIST Figures 9a 9b 9c 9d Ye and 9f rema pane Im 1 amoo Enclosure AquaB 2 SC 2 Ai214300 Label Enclosure AquaBiock2 O o 3 12228 00 LabelKiAquaBlok2 ER 4 TRM 35038 P Label Ground 5 7069500 Stud Grounding ER 6 748613 Flat Washer i3 Medum E 7 773406 Lock Washer 1 4 HelicalSping L 4 8 5565520 Nu 1 4 20UNCHex C 1 9 773407 LockWasher5 f6 HelicaSping Nut ala ajo SSF 8027 ut 10 32 Nylon Lock Screw 3 8 16 X 1 Lg Socket Head Cap Nylon 1 31 A12114 00 Bot M12 X 1 75 70mm Lg Glass Filed Nylon 6 Bolt M12 X 1 75 40mm Lg Glass Filled Nylon 4 33 79001 06 O RingSolventProf____________________ 2 34 At2116 00 Rodiess Cyiinder AquaBlock2 A Screw M6 X 1 50mm Lg Socket Head Cap Stainless Steel 9 4 37 Ai21800 Adapter Block Camiage AquaBlck2 L 1 Screw M6 X 1 25mm Lg Socket Head Cap Stainless Steel LL 4 LSMP0002 00 Push Button Air Valve Actuator I
38. ly connected to the system All electrically conductive objects with the exception of those required by the process must be grounded This includes all metallic fluid lines fittings etc All connections to ground must be made individually from each component The ground lug on the AquaBlock 2 cabinet must be connected to ground The coating material supply to the AquaBlock 2 must be grounded An 18 24 inch length of electrically non conductive fluid line must be used between the grounded fluid supply and the AquaBlock 2 fluid inlet fitting The high voltage interlock from the AquaBlock 2 assembly must be installed and functional Main air supply to the AquaBlock 2 cabinet must be 90 psi 5 psi The fluid inlet pressure at the AquaBlock 2 enclosure must never exceed 100 psi or be less than 20 psi The electrostatic voltage must never exceed 90kV Material to be sprayed in not of an emulsion typed 17 LN 9902 00 3 Ransburg LN 9902 00 3 NOTES AquaBlock 2 Installation AquaBlock 2 Operation 19 OPERATION START UP Air Supply 1 Turn on the air supply to the AquaBlock 2 cabinet and adjust the air pressure to between 85 and 95 psi 90 psi nominal at the inlet to the cabinet Purging the Paint Supply Inlet and Outlet gt The system may be flushed out with a blend of water and solvent Butyl Cellosolve or Butyl Carbitol Check with your coating supplier for recommended cleaning mixtures DO NOT us
39. oper operation of the current meter 2 Feedthe 3 8 inch or8mm OD paintline going to the spray applicator s through the slotted opening in the bottom of the cabinet The tubing should be shielded tubing such as Ransburg part number 74178 01 or if other tubing is used it should be covered with 1 inch or equivalent Polyurethane tubing from the connection inside of the AquaBlock 2 cabinet to the applicator s Connect the tubing to the fitting on the bottom of the 4 way shuttle assembly and the other end to the applicator s gt The paint line exiting the AquaBlock 2 cabinet should notbe broken orcontain addi tional connections from the connection atthe 4 way shuttle assembly to the applicator s If additional connections are required for the addition of flow control system components etc special care must be taken to ensure that the connections do not pass close to ground sources that could cause current leakage or electrical arcing Additionally the use of conductive com ponents such as metal flowmeters or regulators should be limited as much as possible to decrease system capacitance as much as possible LN 9902 00 3 AquaBlock 2 Installation gt Systems utilizing positive displacement pumps for the regulation of the fluid flow to the applicator s must be located after the AquaBlock 2 in the charged fluid stream This is to avoid over pressurization of the Aqua Block 2 system or the paint tubing feeding
40. r more suitable model should be installed for best performance Where competitive models are in use the same test procedure should be applied Our service representatives can assist you in conducting this test A WARNING gt AquaBlock 2 is intended for use with non flammable coating materials The flash point of all coating materials cleaning solvents etc must be greater than 100 F NOTE gt TheAquaBlock 2 is notintended foruse with emulsion type materials If concerned test material thoroughly gt DO NOT USE TAP WATER FOR FLUSHING OR CLEANING Deionized water is the acceptable material LN 9902 00 3 AquaBlock 2 Introduction SPECIFICATIONS Physical Dimensions 30 Wide X 36 High X 13 Deep 76 2 cm Wide X 91 4 cm High X 33 0 cm Deep Weight 110 Ibs Approx 50 Kg Electrical High Voltage 90kV Maximum Mechanical Air Air Supply 90 psi 5 psi 6 2 bar 0 3 bar 10 SCFM Maximum Air required for cylinder sensing curcuit 283 slpm Air Filtration 25 50 Micron Paint Supply Pressure 100 psi Maximum 6 9 bar 20 psi Minimum 1 4 bar Volume See Maximum Pressure Depending on viscosity Temperature 120 F Maximum 49 C Filtration is required for paint water and or solvent supplies connected to the system AquaBlock 2 Introduction DESCRIPTIONS 4 Way Shuttle Assembly The 4 Way Shuttle Assembly consists of a series ofquick disconnects and theirrespective
41. rate then re engage them If a metal scraping sound is heard or they are hard to engage locate the area where the parts are interfering If itis at the top or bottom the eight hex head bolts with have Ransburg to be loosened and the block moved up or down slightly Use the same tightening procedure as stated above Ifthe interference is side to side the appropriate jack screw will have to be tightened or loosened Re engage the disconnects and re check This procedure may have to be preformed severaltimes to achieve proper alignment Aslight interference is acceptable The female disconnect if properly installed with the 030 0 76mm gap is floating and will allow some mis alignment and still function well Perform the same procedure for the opposite set of disconnects If when fin ished the disconnects fully mate when pushed together by hand the alignment is complete Do not tighten the six 6 mounting screws any further when finished FEMALE DISCONNECT MOUNTING BLOCK SCREW 6 PLACES LN 9902 00 3 Ransburg AquaBlock 2 Maintenance NOTES LN 9902 00 3 34 AquaBlock 2 Maintenance Ransburg TROUBLESHOOTING GUIDE General Problem Possible Causes Corrective Action No Paint Flow 1 Quick disconnect not 1 Determine why the quick disconnect is not engaging fully engaging and remove obstruction Ensure quick disconnect shields are fully installed Replace quick discount s 2 Low or no pa
42. rts as well as the white face seal on the threaded end If there are any signs of wear nick pits gouges or ifthe seal has been leaking replace the assembly with new or proceed to the Procedure for Rebuild ing Male and Female AquaBlock 2 Disconnects in the Maintenance section in this manual To reinstall thread the assembly into the plastic block until it stops then final torque to 50 60 Ibs in 5 65 6 78 Nm Reinstall the white plastic shields Female Disconnect Remove the white plastic shields surrounding the female disconnects female disconnects are located on the outer stationary plastic blocks with the tubing attached Using a 30mm socket or wrench unscrew disconnects Examine the front face metal and rubber parts as well as the bore on the threaded end If there is any signs of wear nick pits gouges or if the seal has been leaking replace the assembly with new or proceed to the Procedure for Rebuilding Male and Female AquaBlock 2 Disconnects in the Maintenance section in this manual 31 LN 9902 00 3 Ransburg AquaBlock 2 Maintenance To reinstall the plastic threaded nipples that the disconnect will attach to must have all residual pipe tape removed then replaced Remove all tape from the threads carefully do not damage threads or o rings Apply new thread tape to threads only 6 8 complete turns of tape is required more tape may damage threads and less tape may result in leakage of the assembly
43. s High Voltage 4 Way Shuttle Interlock A pneumatic 3 way valve is located in the top of the AquaBlock cabinet and is activated when the cabinet door is opened This 3 way valve is a normally closed type that supplies air to the bulkhead fitting located in the top of the cabinet and also to a high volume 3 way valve inside of the cabinet when the door is fully closed The pneumatic signal at the bulkhead is intended for an interlock for the high voltage power supply This interlock can be accomplished through a pressure switch to shut down high voltage when the cabinet door is opened The air pilot supplied to the high volume 3 way valve is to interlock the motion of the 4 way shuttle assembly When the door is opened the pilot is removed and the air supply to the actuator is closed off LN 9902 00 3 Ransburg AquaBlock 2 Introduction NOTE gt Ifthe high voltage power supply does not have a pneumatic pressure switch contactyour local Ransburg representative Ww Microamperes System Electrical Current Monitor The electrical circuit that monitors the electro static current that bleeds through the AquaBlock 2 is composed primarily of a microampere meter Possible Damage located on the face of the cabinet The electrical circuit is completed by one wire connected from the paint supply fitting to the meter and another wire from the meter to earth ground The meter provides an indication of the level of current that is pass
44. sing appro priate solvent and a soft rag or soft bristle brush Ransburg 6 Clean the eight 8 Quick Disconnects using an appropriate solvent and a soft rag or soft bristle brush 7 Install the eight 8 Quick Disconnect Shields by turning clockwise and hand tighten 8 Close the AquaBlock 2 cabinet door 9 With paint loaded into the AquaBlock 2 and high voltage applied to the applicator s check the steady state current ofthe AquaBlock 2 system on the current meter on the door of the cabinet refer to Current Meter chart in the Introduction sec tion gt The system may be flushed out with a blend of water and solvent A water solvent mixture Butyl Cellosolve or Butyl Carbitol should be left in the system when not in use Check with your coating supplier for recommended cleaning mixtures DO NOT USE TAP WATER DEIONIZED WATER IS ACCEPTABLE gt Purging the system with compressed air only or a combination of compressed air and flushing fluid may leave deposits of dry coating material in the system which may cause damage to the seals and internal surfaces of the components LN 9902 00 3 Ransburg PREVENTIVE MAINTENANCE NOTE gt Inthe event of a system malfunction a determination of the probable cause should be made using the Trouble shooting Guide in this section The failed sub assembly can then be easily replaced following the instructions below Periodically inspect tubing and fittings
45. to minimize the length of fluid line to be flushed and also minimize the amount of fluid hose that will be charged at high voltage potential Ransburg MOUNTING 1 Mount the unit onto an appropriate structure in or near the spray booth using four bolts 7 16 minimum diameter 2 Ground the unit by attaching the grounding cable provided to a suitable earth ground PNEUMATIC CONNECTIONS 1 From a filtered and regulated air supply con nect 3 8 or 10mm OD tubing to the fitting labeled NOTE The air supply pressure to the Aqua Block 2 system must be between 85 and 95 psi 90 psi nominal AIR SUPPLY on the top of the cabinet 2 Connect 1 4 or6mm OD tubing from the fitting labeled HIGH VOLTAGE INTERLOCK to the appropriate pressure switch connection on the power supply When the cabinet door is open the high voltage power supply is de energized PAINT SUPPLY 1 Connect 3 8 or 8mm OD tubing from the water based coating supply to the fitting labeled FLUID INLET on the top of the cabinet This connection uses a metal fitting which is grounded through the current me ter No other metal fittings should be used to replace plastic connections located on or in this cabinet LN 9902 00 3 Ransburg gt The last 18 24 inches of the paint supply hose connected to the fluid inlet of the enclosure must be made of a non con ductive material This isolated fluid hose is required to ensure pr
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