Ransburg A12148-XX User Manual
Ransburg
SERVICE MANUAL
LN-9902-00.3
(Replaces LN-9902-00.2)
February - 2013
AQUABLOCK
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.)
NOTE: This service manual has been superceded from service manual number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.
Ransburg
LN-9902-00.3
Ransburg
CONTENTS
SAFETY:
AquaBlock 2- Contents
PAGE
1-4
SAFETY PRECAUTIONS...........................................................................................................
HAZARDS / SAFEGUARDS......................................................................................................
INTRODUCTION:
FEATURES..................................................................................................................................
SPECIFICATIONS......................................................................................................................
DESCRIPTIONS.........................................................................................................................
AQUABLOCK 2 MODEL IDENTIFICATION..............................................................................
STANDARD SYSTEM.................................................................................................................
INSTALLATION:
AQUABLOCK 2 LOCATION.......................................................................................................
MOUNTING.................................................................................................................................
PNEUMATIC CONNECTIONS...................................................................................................
PAINT SUPPLY...........................................................................................................................
AQUABLOCK 2 PNEUMATIC AND FLUID SCHEMATIC........................................................
AQUABLOCK 2 ELECTRICAL SCHEMATIC............................................................................
AQUABLOCK 2 SYSTEM W/GEAR PUMP...............................................................................
AQUABLOCK 2 SYSTEM W/FLOWMETER / REGULATOR...................................................
AQUABLOCK 2 INSTALLATION CHECKLIST..........................................................................
OPERATION:
1
2-4
5-10
5-6
6
7-8
9
9
11-18
11
11
11
11-12
13
14
15
16
17
19-20
START-UP...................................................................................................................................
MAINTENANCE:
PERIODIC MAINTENANCE.......................................................................................................
PREVENTIVE MAINTENANCE..................................................................................................
RE-ASSEMBLY...........................................................................................................................
LKIT0018-06 CERAMIC CYLINDER ASSEMBLY (200 CC )/PARTS LIST..............................
TOOLS TO REBUILD DISCONNECTS.....................................................................................
PROCEDURE FOR REBUILDING MALE AND FEMALE
AQUABLOCK 2 DISCONNECTS...............................................................................................
REMOVAL AND INSTALLATION OF MALE AND FEMALE
DISCONNECTS FROM AQUABLOCK 2 ASSEMBLY..............................................................
ALIGNMENT PROCEDURE FOR DISCONNECT COUPLINGS............................................
TROUBLESHOOTING GUIDE...................................................................................................
(Continued On Next Page)
LN-9902-00.3
19
21-36
21
22-23
23
24-25
26
26-31
31-32
33
35-36
AquaBlock 2 - Contents
CONTENTS (Cont.)
Ransburg
PAGE
PARTS IDENTIFICATION:
AQUABLOCK 2 ASSEMBLY PARTS IDENTIFICATION..........................................................
A12148-XX AQUABLOCK 2 PARTS LIST.................................................................................
FITTING SELECTION.................................................................................................................
A12140-01 FITTINGS (METRIC) AND
A12140-02 FITTINGS (FRACTIONAL) / PARTS LIST..............................................................
AQUABLOCK 2 RECOMMENDED SPARE PARTS.................................................................
A12101-00 MALE DISCONNECT ASSEMBLY PARTS............................................................
A12109-00 FEMALE DISCONNECT ASSEMBLY PARTS........................................................
ACCESSORIES..........................................................................................................................
WARRANTY POLICIES:
LIMITED WARRANTY.................................................................................................................
37-48
37-42
43-44
44
45-46
47
47
47
48
49
49
LN-9902-00.3
Ransburg
LN-9902-00.3
AquaBlock 2 - Safety
SAFETY
SAFETY PRECAUTIONS
Ransburg
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 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 specications
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.
W A R N I N G
!
The user MUST read and be familiar
with the Safety Section in this manual and the
Ransburg safety literature therein identied.
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 re codes
and ordinances as well as NFPA-33 SAFETY
STANDARD, prior to installing, operating,
and/or servicing this equipment.
W A R N I N G
!
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.
Careful study and continued use of this manual will
provide a better understanding of the equipment
and process, resulting in more efcient operation,
longer trouble-free service and faster, easier troubleshooting. If you do not have the manuals and
safety literature for your Ransburg system, contact
your local Ransburg representative or Ransburg.
1
LN-9902-00.3
Ransburg
AquaBlock 2 - Safety
AREA
Tells where hazards
may occur.
Spray Area
HAZARD
Tells what the hazard is.
Fire Hazard
Improper or inadequate oper-ation and maintenance
pro-cedures 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
shut-down indicates a problem in the system requiring
correc-tion.
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 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.
When using solvents for cleaning:
Those used for equipment ushing should have ash
points equal to or higher than those of the
coating material.
Those used for general cleaning must have ash
points above 100oF (37.8oC).
Spray booth ventilation must be kept at the rates
required by NFPA-33, OSHA, and local codes. In addition, ventilation must be maintained during cleaning
operations using ammable 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 modications may cause re 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
and operated in accordance with NFPA-33, NEC, and
OSHA requirements.
LN-9902-00.3
2
AquaBlock 2 Safety
Ransburg
AREA
Tells where hazards
may occur.
General Use and
Maintenance
Electrical
Equipment
HAZARD
Tells what the hazard is.
Improper operation or maintenance may create a hazard.
Personnel must be properly
trained in the use of this equipment.
High voltage equipment is utilized. Arcing in areas of ammable or combustible mater-ials
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 shutdown indicates a problem in
the system which requires
correction.
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 with appropriate local, state, and national
codes governing ventilation, re protection, operation 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 I or II, 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 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.
Explosion Hazard/
Incompatible
Materials
3
An electrical arc can ignite coat-
ing materials and cause a re or
explosion.
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.
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, 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
material supplier. Any other type of solvent may
be used with aluminum equipment.
LN-9902-00.3
Ransburg
AquaBlock 2- Safety
AREA
Tells where hazards
may occur.
Toxic Substances
Intended Use
HAZARD
Tells what the hazard is.
Certain material may be harmful if inhaled, or if there is contact with the skin.
Using coating materials and/or
cleaning and ushing solvents
which fave ash points below
100°F (37.8°C) may cause a
re hazard.
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.
LN-9902-00.3
4
AquaBlock 2- Introduction
INTRODUCTION
FEATURES
Ransburg
Over the past several years, the nishing industry
has experienced increasing pressure to meet the
requirements of environmental legislation aimed
at reducing the amount of air pollution being generated 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
which 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 isolated coating supplies became obvious. Isolated
coating supplies require a lot of oor space, the
use of protective fencing around the isolation area,
and in many cases, long delays in production are
experienced to accomplish color change.
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. The AquaBlock 2 cabinet
contains the 4-way shuttle assembly, the cylinder
and pneumatic sensing / switching valves. Because it is pneumatically controlled the AquaBlock
2 can be located inside or outside of hazardous
areas.
The paint enters one port of the 4-way shuttle assembly 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 ow
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 accomp-lished in as little as 60 seconds, depending
on the system conguration.
To respond to this need, Ransburg has developed 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 applicator(s). One AquaBlock 2 can be used for one or
more automatic spray applicators. There is a
5
LN-9902-00.3
Ransburg
AquaBlock 2 - Introduction
NOTE
Most power supplies manufactured by
Ransburg can be used with the AquaBlock
2 System. However, in existing installations where older models are in use, the
high voltage system should be pre-tested
using the recommended test procedure to
determine if a newer, 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.
W A R N I N G
!
The AquaBlock 2 is intended for use
with non-ammable coating materials. The
ash point of all coating materials, cleaning
solvents, etc., must be greater than 100°F.
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 lbs. (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)
NOTE
The AquaBlock 2 is not intended for use
with emulsion type materials. If concerned,
test material thoroughly.
C A U T I O N
!
DO NOT USE TAP WATER FOR
FLUSHING OR CLEANING. Deionized
water is the acceptable material.
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.
LN-9902-00.3
6
AquaBlock 2 - Introduction
DESCRIPTIONS
Ransburg
4-Way Shuttle Assembly
The 4-Way Shuttle Assembly consists of a series
of quick-disconnects and their respective 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 Disconnects 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 ows through another port of the 4-way
shuttle assembly and out to the atomizer. When
the lling side of the cylinder is full, a pneumatic
signal is sent to the actuator that moves the 4-way
shuttle. The ow of paint in the 4-way shuttle is
now switched and the emptied side of the cylinder
is now lling with paint from the grounded paint
supply. The full side of the cylinder is now connected 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 shielded from high voltage
by a series 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.
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 orices built-in to the
90 degree cross tting at the inlet of the 4-way
pneumatic valve which are connected to each of
the pilots. These restricted orices 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 specied 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 uid 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(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 tting 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.
7
LN-9902-00.3
Ransburg
AquaBlock 2 - Introduction
NOTE
If the high voltage power supply does
not have a pneumatic pressure switch,
contact your local Ransburg representative
about adding it to your power supply.
System Electrical Current Monitor
The electrical circuit that monitors the electrostatic current that bleeds through the AquaBlock
2 is composed primarily of a microampere meter
located on the face of the cabinet. The electrical
circuit is completed by one wire connected from
the paint supply tting to the meter and another
wire from the meter to earth ground. The meter
provides an indication of the level of current that
is passing through the AquaBlock 2 from the
electrostatic applicator. This current measurement provides useful information as to the level of
contamination inside the quick disconnect shields,
contamination inside the cabinet, and abnormal
system operation such as quick disconnect (or
uid seal) leakage, etc.
Current Range
(Microamperes)
0-20
20-50
50+
* Possible Damage
Current Meter
Activity
Normal Operation Range
Clean Quick-Disconnect Shields
Shut System Down *
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. If the 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 Identication"
section). Two digits must follow the basic part number, for example:
A12148 - XX
Basic Part Number
* Model number and serial number are located on the face of the rear plate assembly.
(Table A)
Fitting Selection
Figure 1: Standard System
TABLE A - Fitting Selection (Figure 8)
Dash
#
01
02
9
Assembly, AquaBlock 2, Metric
Assembly, AquaBlock 2, Fractional
"A"Description
A12140-01
A12140-02
LN-9902-00.3
Ransburg
AquaBlock 2 - Introduction
NOTES
LN-9902-00.3
10
AquaBlock 2 - Installation
INSTALLATION
Ransburg
W A R N I N G
!
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.
W A R N I N G
!
All AquaBlock 2 installations must com-
ply with appropriate local, state, and national
codes governing ventilation, re protection,
operation, maintenance, and housekeeping.
Refer to OSHA, NFPA-30, NFPA-33,
and customer's insurance requirements.
AQUABLOCK 2 LOCATION
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 ltered and regulated air supply, connect 3/8" or 10mm OD tubing to the tting 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.
The AquaBlock 2 cabinet is installed between the
grounded coating supply and the electrostatic
spray applicator(s). This system provides a “voltage block” to prevent high voltage from following
the conductive path through the water based paint
line connected from the spray applicator(s), which
are at high voltage, and the grounded paint supply.
The unit should be installed near the spray
equipment to minimize the length of uid line to
be ushed and also minimize the amount of uid
hose that will be charged at high voltage potential.
2. Connect 1/4" or 6mm OD tubing from the tting
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 tting labeled
“FLUID INLET” on the top of the cabinet.
C A U T I O N
!
This connection uses a metal tting
which is grounded through the current me-
ter. No other metal ttings should be used
to replace plastic connections located on or
in this cabinet.
11
LN-9902-00.3
Ransburg
AquaBlock 2 - Installation
C A U T I O N
The last 18-24-inches of the paint
supply hose connected to the uid inlet of
the enclosure must be made of a non-con-
ductive material. This isolated uid hose is
required to ensure proper operation of the
current meter.
2. Feed the 3/8-inch or 8mm OD paint line 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 tting on the bottom of the 4-way shuttle
assembly and the other end to the applicator(s).
C A U T I O N
!!
Systems utilizing positive displacement
pumps for the regulation of the uid ow to
the applicator(s) must be located after the
AquaBlock 2 in the charged uid stream. This
is to avoid over-pressurization of the AquaBlock 2 system, or the paint tubing feeding
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 ow control system, and Figure 5 shows a
typical system with an isolated owmeter and uid
regulator ow control system.
C A U T I O N
!
The paint line exiting the AquaBlock 2
cabinet should not be broken, or contain additional connections, from the connection at the
4-way shuttle assembly to the applicator(s).
If additional connections are required, for the
addition of ow 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 owmeters or regulators, should
be limited as much as possible to decrease
system capacitance as much as possible.
LN-9902-00.3
12
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