Sponge-Jet Feed Unit User Manual

Transcription

1 Spnge-Jet Spnge Blasting System Spnge-Jet Feed Unit User Manual Mdels: 100-HP 100-HP-CE 100-HP-J 200-HP 200-HP-CE Headquarters/Manufactured By: Spnge-Jet, Inc. (USA) 14 Pattersn Lane, Newingtn, NH / Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual - 8-December-2011

2 Table f Cntents Sectin Page 1.0 Intrductin Safety Checklist Requirements Operatin Maintenance Trubleshting 18 Ntes 27 Addendum 28 IMPORTANT NOTE: While parts, systems, cmpnents, peratinal prcedures may be the same between equipment mdels, the images prvided in this manual may vary frm mdel t mdel. This manual represents the fllwing mdels and their apprximate wrking capacity: Mdel: 100-HP 100-HP-CE 100-HP-J 200-HP 200-HP-CE Wrking Capacity: 100 liters 100 liters 100 liters 200 liters 200 liters English Language is Original Instructins. Translated frm Original Instructins.

3 1.0 Intrductin 1 Basic Cmpnents 2 1: Hpper Lid (Optinal) 2: Hpper 3: Pressure Vessel 4: Handhle Cver 5: Crab Assembly 6: Twinline Quick Cnnect Fittings 7: Chke Valve 5 8: Auger Tunnel End Cap 9: Blast Hse Cnnectin 4 10: Air Mtr Misture Separatr 11: Air Mtr Lubricatr 3 12: Clean Out Trap 13: Air Mtr 14: Auger Chain Guard and Manual Rtatin Knb 15: Media Actuatr 16: Pp-up 17: Actuatr Tree and Chain Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 3 f 27

4 Basic Cmpnents (cntinued) 18: Exhaust Valve 19: Exhaust Muffler 20: Emergency Stp Buttn 21: Line Pressure Gauge 22: Blast Pressure Regulatr Handle 23: Blast Pressure Gauge 24: Media Feed Pressure Regulatr Handle 25: Media Feed Pressure Gauge 26: Cntrl Panel Misture Separatr 27: Cntrl Panel 28: Actuatin Rate Indicatr Eye 29: Main Air Ball Valve 30. Supply Line Cnnectin 31: On/Off Cntrl Valve 32: Secndary Water Separatr 33: Blast Pressure Regulatr 34: Blast Hse 35: Nzzle Hlder 36: Nzzle 37: Twinline 38: Deadman Handle Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 4 f 27

5 2.0 Safety Checklist O ENSURE THE CAPACITY OF THE OVER-PRESSURE RELIEF VALVE EQUALS OR EXCEEDS THE CAPACITY OF THE COMPRESSED AIR SUPPLY. This Unit is equipped with an Emergency Stp System. Its lcatin and usage shuld be understd befre peratin. This Unit is a pressurized system. Only trained peratrs shuld adjust, maintain and repair it. Inbund pressure shuld never exceed 8.6bar (125psi) regardless f mdel. T prevent electrstatic buildup and pssible electric discharge, the unit and wrk piece must be prperly grunded / bnded. Operatrs and peple in prximity t blasting shuld always wear eye and hearing prtectin with apprpriate respiratry equipment and clthing, which may depend n the type f cating r cntaminant being remved. The peratr and anyne within 1m (3ft) f the nzzle can be expsed t sund emissin in excess f 120 db(a) Never pint the Blast Nzzle twards yurself r thers. Use f nn-supprted Spnge-Jet Deadman handles may cause unintentinal start-up, unreliable shut dwn and can result in persnal injury. Never perfrm maintenance r repairs when the unit is pressurized. Never perate the machine with any wrn r malfunctining cmpnent. Never weld r make mdificatins t the pressure vessel as this will vid certificatins. Befre Feed Unit Pressurizatin and Operatin: Verify this Unit is secure and stable. All pneumatic lines shuld be inspected fr hles, wear and prper fit. The Handhle Cver must be in place and secure prir t and during peratin. Safety pins and restraints shuld be fitted at all Air Supply Hse and Blast Hse cuplings t prevent accidental discnnectin. D nt perate withut the Auger Chain Guard in place. Befre all activities (ther than nrmal peratin), ensure the entire system is depressurized. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 5 f 27

6 3.0 Requirements 3.1 Air Supply / Cmpressr _ Clean, dry cmpressed air must be supplied in adequate vlume and pressure t accmmdate nzzle size at the desired blast pressure. Inbund pressure is typically 8.6bar (125psi), minimum 1bar (15psi) Nte: High humidity envirnments require additinal misture separatrs. (Metric) m 3 /min Requirements Nzzle Size 4.1bar 4.8bar 5.5bar 6.2bar 6.9bar 8.3bar N. 6 Nzzle mm Feed Unit Reserve Ttal N. 7 Nzzle mm Feed Unit Reserve Ttal N. 8 Nzzle mm Feed Unit Reserve Ttal N. 10 Nzzle mm Feed Unit Reserve Ttal N. 12 Nzzle mm Feed Unit Reserve Ttal Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 6 f 27

7 Nzzle Size N mm 3/8in N. 7 11mm 7/16in N mm 1/2in N mm 5/8in N mm 3/4in (Imperial) CFM Requirements 60psi 4.1bar 70psi 4.8bar 80psi 5.5bar 90psi 6.2bar 100psi 6.9bar 120psi 8.3bar Nzzle Feed Unit Reserve Ttal Nzzle Feed Unit Reserve Ttal Nzzle Feed Unit Reserve Ttal Nzzle Feed Unit Reserve Ttal Nzzle ,010 Feed Unit Reserve Ttal ,008 1, Air Supply Requirements This Unit has a 50mm (2in) standard pipe typically fitted with a 50mm (2in) universal crwft (4 lug) cupling. The air supply hse shuld be fitted with a mating cnnectr r replace bth cnnectrs as desired. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 7 f 27

8 Fr supply hse up t 50m (150ft) use a Minimum Air Line Internal Diameter (I.D.) as listed belw. Fr lengths 50 t 90m (150 t 300ft) use a minimum f ne diameter size greater than listed belw. Larger hses decrease pressure lss. NOTE: Occasinally a cmpressr is equipped with undersized utlets. The cmpressr air utlet shuld be n smaller than the recmmended Supply diameters belw. Nzzle Number/Orifice Minimum Air Line I.D. #6 / 9.5mm (3/8in) 38mm (1½in) #7 / 11mm (7/16in) 50mm (2in) #8 / 12.5mm (1/2in) 50mm (2in) #10 / 16mm (5/8in) 64mm (2½in) #12 / 19mm (3/4in) 76mm (3in) 3.3 Blast Hses _ Spnge Media abrasive has been successfully blasted thrugh 90m (300ft) f Blast Hse. Hwever, when chsing between lng Air Supply Hses r lng Blast Hses, keep the Blast Hses as shrt as practical. Belw are recmmended maximum lengths f Blast Hses: Up t 15m (50ft) use 32mm (1.25in) I.D. Whipline cnnected t the unit r t a blast hse extensin. Extensins up t 30m (100ft) must have a minimum 32mm (1.25in) I.D. Extensins ver 30m (100ft) shall use a minimum 38mm (1.5in) I.D. Blast Hse Extensin. Larger hses decrease pressure lss. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 8 f 27

9 3.4 Ambient Temperature _ 32º F 0º C Ambient temperature shuld be abve 0 Celsius (32 Fahrenheit). Otherwise: a) Use winter grade pneumatic tl il in lubricatr. b) Minimize misture in supply air. c) Ice build-up in cntrls r vessel may require thawing prir t restarting machine. Minimize dwn time that might result in freezing. 3.5 Cntainment Cntainment is an integral part f the Spnge-Jet prcess, as Spnge-Jet Spnge Media is recyclable. T take advantage f this, cntainment must be used t capture and recycle Spnge Media. Spnge-Jet is easily cntainable with light plastic sheeting r mesh. Prjects invlving hazardus materials, high wind lad r ther cnditins may require mre cmplex cntainment and negative air dust cllectin. Pre-cleaning f the area will minimize bth dust and debris which can als cause equipment malfunctins. Always fllw lcal, state and federal guidelines cncerning prper cntainment, cntainment ventilatin and mnitring prcedures. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 9 f 27

10 4.0 Operatin This equipment is designed t be perated in a manner cnsistent nly with the instructins cntained in this manual. Befre Feed Unit Pressurizatin and Operatin: Verify the Feed Unit is secure and stable. All pneumatic lines shuld be inspected fr hles, wear and prper fit. The Handhle Cver must be in place and secure prir t and during peratin. Safety pins and restraints shuld be fitted at all Air Supply Hse and Blast Hse cuplings t prevent accidental discnnectin. D nt perate withut Auger Chain Guard in place. Befre all activities (ther than nrmal peratin), ensure entire system is depressurized. 4.1 Operatin f the Feed Unit _ Verify that the unit is secured in an apprpriate manner fr peratin. Inspect all Blast Hse and cnnectins. Repair r replace wrn r damaged cmpnents. Ensure all cuplings are equipped with cupling gaskets, safety pins and hse restraints. Cnfirm all are prperly installed. Cnnect cmpressr t Supply Line Cnnectin and secure safety pins and restraints. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 10 f 27

11 Attach Handhle Cver with gasket in place. _ Cnnect Blast Hse and secure with safety pins. _ Cnfirm Chke Valve is pen. _ Cnnect Return and Supply Twinline Quick Cnnect Fittings. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 11 f 27

12 Fill Feed Unit thrugh Hpper. _ Check Main Air Ball Valve is in clsed psitin then charge supply line. _ Open Main Air Ball Valve. _ Pull the Emergency Stp Buttn t the pen psitin. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 12 f 27

13 _ T begin blasting, unlck Deadman Handle by depressing safety flap. _ Depress Deadman Handle and wait 5 t 10 secnds fr Spnge Media t flw. _ Adjust Blast Pressure and Media Feed Pressure t desired levels. Typical Media Feed Pressures Nzzle Size Spnge Media Recycles Wrking Mix #7 10mm 7/16in #8 12mm 1/2in #10 15mm 5/8in #12 18mm 3/4in _ Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 13 f 27

14 Cnfirm Manual Rtatin Knb is rtating, air mtr lubricatr rate is 1-2 drps per minute and Actuatin Rate Indicatr eye is functining - by seeing it cycle between black and green. Prepare surface t desired cnditin. 4.2 Shutdwn f the Feed Unit _ Nrmal shutdwn during peratin is by releasing Deadman Handle. Alternatively, the Emergency Stp Buttn may be used. Nte: During inspectin, maintenance r any nn-peratinal activity, always shut ff (push in) Emergency Stp Valve. Clse Main Air Ball Valve, shut dwn cmpressr and clse cmpressr supply line ball valve. After cmpressr has cmpletely shutdwn, pen Main Air Ball Valve. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 14 f 27

15 _ Pint Blast Nzzle at wrking substrate (away frm peple) and depress safety flap and then Deadman Handle. Keep Deadman Handle depressed until all remaining air is vented. _ Once all Cntrl Panel gauges read 0 psi, cnfirm that the supply line frm the cmpressr is depressurized. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 15 f 27

16 5.0 Maintenance Rutine maintenance is required t prvide lng and reliable equipment life. This Unit must be shut dwn and fully depressurized prir t any maintenance. Prir t each use: _ Inspect Blast Nzzle fr wear. Once nzzle thrat has wrn 1.5mm (1/16in) beynd its riginal intended diameter, it shuld be replaced. Thrughly inspect Blast Hse cmpnents and cnnectins. Replace hse. Ensure all cuplings are prperly equipped with cupling gaskets, safety pins and hse restraints. Inspect and clean Exhaust Muffler. Replace when exhaust is slw. Remve any accumulated media in Exhaust Muffler and reinstall. WARNING: D n perate equipment withut Exhaust muffler in place. Cnfirm adequate pneumatic tl il is present in Air Mtr Lubricatr. USE SAE 5W (ISO 32) NON-DETERGENT OIL ONLY Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 16 f 27

17 T be perfrmed after every 80 hurs f peratin: Remve lwer, threaded prtin f the Secndary Water Separatr, Cntrl Panel Misture Separatr and Air Mtr Misture Separatr and inspect interir and O-Ring. Remve any cntaminants; replace O-Ring if needed and reinstall. Perfrmed mnthly (r as needed): _ Remve Auger Chain Guard and inspect Auger Drive Chain. Apply lightweight lubricating il as necessary then replace Auger Chain Guard. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 17 f 27

18 6.0 Trubleshting Unit des nt perate when Deadman Handle is depressed Check Main Air Ball Valve is pen. Check Emergency Stp Buttn is pulled ut. Check Twinline Quick Cnnect Fittings are cnnected and secure. Check fr damage t Twinline. Check Line Pressure is abve 1bar(15psi) when Deadman is depressed. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 18 f 27

19 elsdjfsdlkjs Unit des nt perate when Deadman Handle is depressed (Cntinued) Remve red air line frm Exhaust Valve; cver with thumb, then depress Deadman Handle. IF n air is felt exiting red air line, trace air flw peratin thrugh Twinline and Deadman Handle checking fr bstructins r leaks. IF air is felt exiting red air line, place thumb n pening f red air line and depress Deadman Handle. IF unit starts (air exits nzzle) depressurize unit and replace Exhaust Valve Diaphragm. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 19 f 27

20 Air will nt stp exiting nzzle when Deadman Handle is released Push Emergency Stp Buttn (in). If unit stps, likely prblems are: 1. Incrrect Deadman. Replace with Spnge-Jet Deadman. 2. Twinline air lines frm unit t Deadman have been reversed. SUPPLY RETURN RETURN SUPPLY 3. Deadman is brken; replace with Spnge-Jet Deadman. If Unit des nt stp, likely prblems are: 1. On/Off Cntrl Valve is malfunctining. 2. Exhaust Valve Diaphragm is damaged. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 20 f 27

21 Air Mtr sticks during startup; becmes sluggish at lwer Media Pressures Check Air Mtr Lubricatr il level and il lubricatin rate. Auger will nt begin rtating Cnfirm Media Feed Pressure Gauge reads cnsistently with Typical Media Feed Pressure chart n Cntrl Panel Turn Manual Rtatin Knb Regulatr Handle clckwise t start the rtatin. If excessive frce is required, clear bstructin (see next sectin). Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 21 f 27

22 Auger stps rtating during nrmal peratin 1. Release Deadman Handle and depressurize unit. 2. Clse Main Air Ball Valve. 3. Depress Emergency Stp Buttn. 4. Remve Clean Out Trap; rtate Manual Rtatin Knb clckwise and cunter-clckwise until bstructin falls ut. Auger shuld mve smthly. Replace Clean Out Trap. 5. If bstructin cannt be cleared: a. Remve Auger Chain Guard and Chain. b. Remve fur screws, pull Auger frm shaft and remve bstructin. c. Reassemble Auger; test fr smth rtatin. d. Re-install Auger Chain Guard and Chain. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 22 f 27

23 Air flw thrugh nzzle suddenly stps 1. D nt restart. Depress Emergency Stp Buttn immediately. Depressurize unit and clse Main Air Ball Valve. 2. Remve Blast Nzzle frm Blast Hse; inspect fr and remve bstructins. 3. Discnnect all Blast Hse cnnectins; inspect fr and remve bstructins. 4. Remve Auger Tunnel End Cap; check fr and remve bstructins. Replace Auger Tunnel End Cap. 5. If bstructin was frm Spnge Media, turn Media Feed Pressure t 0 bar(0 psi). Check Chke Valve is in full pen psitin; r parallel t pipe. Resume blasting. When stream f air withut Spnge Media is achieved, slwly return Media Feed Pressure Gauge t desired pressure. T much Spnge Media exits Nzzle r is pulsing 1. Check Chke Valve is in full pen psitin; r parallel t pipe. 2. Check Media Feed Pressure Gauge belw 3.4bar (50psi). Resume Blasting. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 23 f 27

24 Blast Pressure increases and decreases cntinuusly r Unit exhausts intermittently while blasting 1. Check fr damage t Twinline and fr air leaks at all fittings and cnnectins. Repair, replace r tighten as necessary. 2. Remve Exhaust Valve Cver, inspect fr and remve bstructins. Check Exhaust Diaphragm fr rips r small hles. Clean r replace as necessary. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 24 f 27

25 Air flws thrugh Nzzle withut Spnge Media while Auger is rtating After depressing Deadman, Spnge Media flw thrugh Nzzle can take up t ±15 secnds with nrmal hse length. Stabilized Spnge Media flw can take up t ±4 minutes. 1. Check fr adequate Spnge Media amunt in Pressure Vessel. 2. Check Actuatin Rate Indicatr Eye is cycling between black and green every few secnds while machine is pressurized and Deadman Handle is depressed. If Actuatin Rate Indicatr Eye is cycling, depressurize unit, pen Handhle Cver and check Media Actuatr and Actuatr Tree and Chain are attached. Recnnect if necessary and lk fr bstructin in bttm f Pressure Vessel. If Actuatin Rate Indicatr Eye is nt cycling, enter Diagnstic Mde. Diagnstic Mde: 1. Turn Blast Pressure Regulatr Handle ff by rtating until it remves frm Cntrl Panel. 2. Turn Media Feed Pressure Regulatr Handle ff by rtating until it remves frm Cntrl Panel. 3. Remve Handhle Cver and Spnge Media s Actuatr Tree and Chain are visible. 4. Depress Deadman Handle 5. Actuatr Tree and Chain shuld be alternating <90 every 2-4 secnd - depending n initial setting. If Actuatr Tree and Chain are cycling, then Actuatin Rate Indicatr Eye may need replacement but shuld nt effect verall peratin. Shut ff unit and inspect fr bstructins in the bttm f Pressure Vessel and pipe feeding Auger. If Actuatr Tree and Chain are nt cycling, then Remve tp range utput airline n Desiccant Filter, depress Deadman Handle; check tp f Desiccant Filter fr cntinuus airflw. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 25 f 27

26 Air flws thrugh Nzzle withut Spnge Media while Auger is rtating (Cntinued) If n airflw is felt frm the tp f Desiccant Filter, replace Desiccant Filter matching airline psitins prir t remval. It is necessary t switch airline fittings frm ld filter t new. Re-check tp f Desiccant Filter fr cntinuus airflw. Check cycling f Actuatin Rate Indicatr Eye and fr light pulse f air exiting Timer. Cnfirm Timer is set between If Actuatin Rate Indicatr Eye and Timer test successfully, resume blasting. If n light pulse f air is exiting tp f Timer, then Remve tw nuts frm Timer base, then remve screws frm Timer face; replace the Timer, matching airline psitins prir t remval. Cnfirm prper mtin f Actuatin Indicatr Eye and Actuatr Tree Assembly. Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 26 f 27

27 NOTES: MODEL#: SERIAL#: Spnge-Jet 100-HP / 100-HP-CE / 100-HP-J / 200-HP / 200-HP-CE User Manual Page 27 f 27

28 Dry, Lw Dust Abrasive Blasting Technlgy Spnge-Jet, Inc. 14 Pattersn Lane, Newingtn, NH USA / USA / Fax: We Of: EC Declaratin f Cnfrmity Spnge Jet Inc. 14 Pattersn Lane, Newingtn, N.H Telephne Inquiries t: sjadmin@spngejet.cm Hereby declare that: Equipment: Mdel: Serial Number: Year f cnstructin: Spnge-Jet Feed Unit Vessel 100-HP-CE r 200-HP-CE XXXX XXXX Is in cnfrmity with the applicable requirements f the fllwing standard dcuments The Directives cvered by this Declaratin: Eurpean Pressure Vessels Directive: (PED) 97/23/EC Machinery Directive: 2006/42/EC (Frmerly 98/37/EC) The PED Directive 97/23/EC Standards: EN (Apprval f Welding Prcedure) The Machinery Directive 2006/42/EC Standards: EN :2000+A1: (Hand Held Nn-Electric Pwer Tls) EN ISO (Safety f Machinery Risk Assessment) I hereby declare that the equipment named abve has been designed t cmply With the relevant sectins f the abve referenced specificatins. The unit cmplies With all applicable Essential Requirements f the Directives. Signed: Name: Michael T. Merritt Psitin: President On This Date: XX/XX/XXXX Authrised Representative: Eurlink (Eurpe) limited Avaln Huse Marcham Rad Abingdn OX14 1UD UK