AIRBRASIVE K II Series User manual

1
AIRBRASIVE® UNIT
MODEL K SERIES II
220V/50Hz
AU802
Service Manual
Operation & Maintenance Instructions with Illustrated Parts List
Airbrasive Jet Technologies, LLC
3461 South Clinton Avenue
South Plainfield, NJ 07080
Email: [email protected]
Phone: [phone]
www.airbrasive.com
Revised: December 2022

2
Overview
AIRBRASIVE® MICRO ABRASIVE BLASTING TECHNOLOGY
Airbrasive® Jet Machining is a process in which high pressure air and very fine powder are blended in a chamber to form
an abrasive mixture. This mixture is then sent through a small, precisely machined nozzle. The result is a highly accurate
abrasive stream that can be used for cleaning, cutting, drilling, deburring, and finishing all types of surfaces. Airbrasive®
Machines have limitless applications. These highly engineered machines are incredibly versatile. They have the power to
cut and drill materials as hard as diamonds, as well as the precision to delicately clean debris from ancient papyrus
documents.
OPERATING PRINCIPLES
The Airbrasive® Machine is capable of many cutting and abrading tasks. From cutting very hard materials such as diamonds
to cleaning extremely delicate items like fabric or paper. The key to taking advantage of its versatility is the knowledge of
how it cuts. Knowing this, you can properly set the various controls to achieve your desired cutting results. There are six
key variables involved in the cutting process. 1) Air Pressure, 2) Powder Flow Rate, 3) Nozzle Size, 4) Type of Powder, 5)
Nozzle Distance from work piece, and 6) Angle of Impingement.
AIR PRESSURE
The air pressure is directly related to the velocity of the powder particles striking your work piece. The higher the air
pressure the faster the particles and the greater the cutting speed. The lower the pressure the, lower the cutting speed.
This is not a linear correlation. There are certain critical points you will notice as you experiment with different air pressure
settings. When the particle velocity falls below a certain level the cutting action may suddenly stop altogether. Similarly, a
small increase in air pressure may gain a large increase in cutting action. The air pressure is limited at the high end by safety
concerns and by what your main air supply can produce.
The unit should never be pressurized beyond 140 PSI!
POWDER FLOW RATE
The amount of powder exiting the nozzle per minute is referred to as the flow rate. The greater the flow rate, the greater
the cutting action. To achieve the better cutting action with higher powder flow rates, it is often necessary to increase the
air pressure. This is done to maintain particle velocity which tends to slow down as the mass the air stream must carry
increases. Cutting action will decrease quickly at very high powder flow rates. This is due to interference between the
powder particles bouncing off the work piece and those coming out of the nozzle. Some brief experimentation at these
high flow rates will quickly reveal your limits.
NOZZLE SIZE
Nozzle orifices are shaped to be either round or rectangular. The nozzle widths vary in size from .005 up to .032 inches.
The size of the nozzle determines the area that will be impacted by the powder. The larger the nozzle, the greater the area.
The shape of the nozzle is important for getting into unusually shaped spaces. A rectangular nozzle can lightly cover a large
width or, when turned, heavily impact a narrow space.
TYPE OF POWDER
The cutting powder is the most important variable in the "Airbrasive" process. It determines the severity with which you
will impact your part. Some powders are designed for aggressive removal of material while others for a gentle cleaning. To
achieve consistent, sputter free smooth flow it is necessary to use uniformly sized powder. If the powder particles vary in
size, even a little, the powder will tend to clump together. This happens because the smaller particles fill in the gaps
between the larger particles, effectively locking them all together. If all the particles are of the same size, then this locking
action cannot take place.
NOZZLE DISTANCE TO WORKPIECE
The distance you hold the nozzle from the work piece plays a large part in determining the area covered as well as the
cutting rate.

3
ANGLE OF IMPINGEMENT
The angle at which you hold the nozzle regulates the speed and efficiency by which material can be removed from the
work piece. There are two theories at play here, one based on material removal by brittle failure and the other on material
removal by ductile failure. Brittle failure occurs when impacting powder granules penetrate the work surface and literally
blast particles out of it. Ductile failure occurs when the powder granule strikes the work surface at an angle of less than 90
degrees and removes material by generating a chip.
Tests have shown that maximum material removal for ductile materials occurs between a 15- and 45-degree angle of
incidence. For a brittle material, maximum removal occurs at an angle of 90 degrees.

4
Section 1: Introduction and Description
INTRODUCTION
A. Scope. This technical manual contains operation and service instructions, as well as an illustrated parts list for the
Airbrasive® Model K Series II manufactured by Airbrasive Jet Technologies, LLC.
B. Characteristics. The Airbrasive® Model K Series II is an electrically powered device that incorporates a patented electro-
magnetic vibratory feed system for powder delivery. The Model K series II unit has been designed to accommodate both
the intermittent and continuous production demands of high-volume producers.
SPECIFICATIONS
1. Air Supply Requirements
110 ± 30 PSI (0.5 CFM @ 80 PSI min., 140 PSI max.)
Dry, clean, compressed air, carbon dioxide, or nitrogen.
2. Electrical Power Requirements
AU802: 220V, 50HZ, Single Phase, Three Wire The plug supplied is three-
prong, polarized, providing an earth ground.
3. Weight
33 lbs. (15.0 kg)
4. Dimensions
13” x 12” x 12” (H x W x D)
33.0 cm x 30.5 cm x 30.5 cm (H x W x D)
WARNING: The use of oxygen as a gas supply presents the possibility of an explosion occurring. Under no
circumstances should oxygen be used.
IMPORTANT: A suitable dust collector system is required to maintain operator's exposures to powder dusts below
permissible exposure limits such as those regulated by OSHA or recommended annually by ACGIH (American Conference
of Governmental Industrial Hygienist). Consult the manufacturer of the dust collector equipment for the correct filter for
other dusts or air contaminants resulting from material being abraded.
AIR SUPPLY NOTE
Many compressed air lines are contaminated with moisture, oil, and dirt, which are detrimental to the performance and
operation of the Unit. Moisture filters and unloaders must be used. These items can be purchased directly from Airbrasive
Jet Technologies, LLC.
POWDER NOTE
The MODEL K UNIT is designed to use specially prepared powders that are meticulously screened for uniform particle
size. These specialty powders insure smooth flow through the many precision ports and feedthroughs. The use of any
other type of powder can result in clogging of the internal components and potential damage to the unit. For more
information on these powders, contact Airbrasive Jet Technologies, LLC at [phone].
AIRBRASIVE® MODEL K II: STANDARD EQUIPMENT
Description
Part Number
Quantity
Airbrasive® Model K
AU802
1
Air Supply Hose
AT122
5 ft
Nozzle (Rt. Angle .018” I.D)
AN118
1
Nozzle (Straight, Round, .018” I.D.)
AN119
1
Nozzle (Straight, Rectangular, .006” x.060”)
AN124
1
AccuBrade 27 –Aluminum Oxide
AP101
4 lbs.
AccuBrade 50 –Aluminum Oxide
AP105
4 lbs.
Funnel
AM206
1
Hex T-handle, 3/16” – 9”
AM244
1

5
Section 1a: Description of Components (Sorted Alphabetically by Part #)
AC153X | MIXING CHAMBER ASSEMBLY
When the mixing chamber is vibrated, powder falls through small holes in the orifice plate assembly and is entrained into
the air stream flowing through the chamber base. This is where the air and powder are precisely blended into the mixture
you need for your application.
AE104 | FUSE HOLDER SOCKET
Holds a 2.5A electric fuse.
AE130X | POWDER REGULATION ADJUSTMENT
This knob adjusts the voltage being applied to the vibrator/mixing chamber assembly. It regulates the powder flow rate
exiting the nozzle
AE153X | PRESSURE SWITCH ASSEMBLY
Converts pneumatic pressure into an electric signal to operate the Vibrator.
AE182 | POWER OUTLET
Your external power source is connected here.
AG105Y | AIR PRESSURE INDICATOR
This tells you if your incoming air line pressure is available.
AG107 | POWDER REGULATION GAUGE
A relative measurement of how much powder is entering the flow stream. The gauge measures voltage being applied to
the vibrator/mixing chamber assembly. The higher the voltage, the greater the vibration and resultant powder flow.
AG111 | CHAMBER PRESSURE GAUGE
A measure of the air pressure in the mixing chamber, auxiliary chamber. This is the air pressure that will be seen at the
nozzle. Do not attempt to open auxiliary chamber to refill powder until this gauge reads "0 psi". This gauge is not field
repairable and should be replaced with a new one if it malfunctions
AH101Y | HAND PIECE ASSEMBLY
Comprises of the tube/hose, the hand piece and end fitting where the nozzle is threaded.
AM258X | SYSTEM POWER ON/OFF SWITCH
The master switch for electrical current supplied to the unit. This will initiate bleeding of all pneumatic lines when switched
off during use. Allow a minimum of 20 seconds after turning system power off before attempting to open powder chamber;
it takes this long for all pneumatic lines to bleed off and reduce pressure in the chamber to safe levels.
AQ104 | AIR IN
External air source is connected here.
AR105X | FOOT SWITCH
Actuates the powder flow to allow for a hands-free operation.
AR106X | FILTER ASSEMBLY
Filters the air and powder mixture and assures its flow in the correct direction.