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ProFormer™ Operating Manual

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1. Item Description Number 290182 Exhaust valve MG 78 with ceramic restrictor kit 290184 Boron carbide upgrade for restrictor kit extended wear Factory Installed option 502081 Boron carbide upgrade replacement restrictor 2S s za TI Aa mo A f 4 i THES a X HN Exhaust Valve Components Item Part Number Description 290183 Rebuild Kit MG 78 Seat amp gasket ball diaphragm 3 screws drawing items 2 3 4 14 Note MG 78 castings must be in good condition to use PN 290183 effectively 1 753332 Valve body 2 753412 Seat valve ball steel 3 524132 Gasket seat 4 525322 Valve ball also used on 411 amp 412 valves 5 553412 Spacer washer steel 1 2 ID x 2 OD x 1 4 thick 6 753392 Spacer ring inner 7 753402 Spacer ring outer 8 523672 Diaphragm 2 per assembly 9 753382 Cover valve 10 552842 Washer 1 2 ID x 2 OD x 1 16 thick 11 551962 Bolt 1 2 13 x 1 3 4 Page 46 Empire Abrasive Equipment Company 12 553982 Bolt 3 8 16 x 2 13 552762 Lock washer 3 8 14 551122 Screws seat 1 4 20 x 1 2 pack of 3 15 544512 Reducer bushing 1 1 4 MPT x 1 FPT 16 520181 Hose Barb 1 Restrictor Parts 290218 Ceramic Restrictor kit standard 17 502431 Ceramic nozzle standard 502081 Boron carbide upgrade for restrictor kit customer installed extended wear 290184 Bo
2. Parts 9 1 Reclaimer Item 1 2 2700741 AA 3 770788 Doonrecdaime O 7 Plug 1 NPT Suction systems only 1 1 Bolt i 552542 Nut 3 8 16 1 gun suction systems 8 required 522762 Lock Washer 3 8 Screen coarse 11 1 2 OD 4 Mesh S 1 1 creen flat 5 16 13 OD 2 3 14 739041 Screen fine 11 1 2 OD 8 Mesh 5 6 Page 41 Empire Abrasive Equipment Company 9 2 Pressure Blast Systems Parts for Blast Hose Assembly Standard 1 2 Number Number Nozzle Washer Ceramic nozzles 5 8 ID 10 pack Nozzle Washer Di Carb Boron 1 2 ID 10 pack 6 524101 AHCW Coupling Washer 10 pack 525102 AHCW Coupling Washer 25 pack 1 x 1 3 8 Grommet blast hose 7 523931 8 x 554242 3 8 Screws 4 pack 9 510511 Safety pin 564822 Tag safety screw coupling 520792 PBH 1 2 Blast Hose Maximum length 50 Page 42 Empire Abrasive Equipment Company MJ S Blast amp Air Hoses E m ednine E one 140302 140303 Air hose assembly 1 ID 520912 A ME O Al os nih Air hose length Po 522541 521672 Blast hose assembly 1 2 ID see previous chart 520792 A CCC Blast hose 1 2 ID pS Blast hose length std cabinet Exhaust Hose Exhaust hose assembly with 1 NPT barb ends 5 for 1 cu ft vessel Exhaust hose 1 ID blast hose Maximum length 50 Hose barb 1 NPT x 1 ID hose
3. Figure 1 ProFormer Cabinet System Page 5 Empire Abrasive Equipment Company 1 0 Installation 1 1 Hand Tools Required The following tools are recommended for the mechanical installation of your ProFormer Cabinet system e 6 adjustable wrench e 9 16 wrench or socket e 14 Pipe wrenches e Channel Lock Pliers e medium Phillips head screwdriver e medium flat blade screwdriver 1 2 Preparing for Installation Your ProFormer system is fully assembled Compressed air earth ground and electric power are all that need to be connected The equipment must be placed on a level surface Do not install your ProFormer system on a floor subject to wet conditions 1 3 Getting Started Step 1 Unwrap and remove the cabinet from the pallet Step 2 Using the built in forklift channels at the bottom of the cabinet move the system to the installation location Step 3 Insure there is adequate space on both sides of the cabinet for full opening of part loading unloading and maintenance access doors PF3642 cabinets require 37 inches and PF 4652 cabinets require 44 inches on each side of the cabinet 1 4 Positioning the ProFormer System Step 1 Place the cabinet and stabilize it by adjusting the leveling bolts to compensate for any unevenness in the floor Step 2 Insure that there is adequate space at both sides of the system for easy access to components such as the reclaimer on the left hand side and the dust drum and dus
4. see section 6 2 Troubleshooting the Pneumatic Control Circuit Problem Poor production rate Probable Cause Remedy Low blast air pressure Increase pressure within the specified range Nozzle too small the smaller the nozzle the smaller the blast pattern Install a larger nozzle and air jet on suction systems to accommodate your production needs Improper media See section 4 1 Media Selection and Use Improper media flow See section 3 0 Equipment Adjustments Low media level Add media to maintain recommended level Parts to be blasted are oily or wet Parts to be processed must be absolutely dry and free of oil grease etc Media has high dust content Blast media breaks down and must be replaced on a regular basis Remove old media from system and replace with new Adjust reclaimer tuning band See section 3 3 Equipment Adjustments Problem Static char ge build up and discharge irritates the operator Probable Cause Remedy Low quality blast hose poor conductor of static charge Replace blast hose with one of high quality Static charges are created and build up by the air and media moving at high velocity through the blast hose System grounded improperly Earth ground the system Part insulated resting on rubber mat Place part on metal surface i e cabinet floor or turntable top Low comp
5. zane gt O 510821 _ Glov lethand 9 520561 3 Clamp 8 per glove 10 555016 Cd Glove Hole Flange Plastic 12 52501 Bumper urethane O ist 821500 IntelockHose o Z 14 509071 Latch Door w o Handle Hole O o o ate Door o oo o a a o 16 50981 CC Spacer Catch Shim Only 16A 300016 3 LetchKitItems14 15 amp 16 17 5020 Gauge Minihelic 18 504101 A Mama Pushbutton 2 required_ 19 50011 DustBucke 5Galon 20 76503 765043 RoofCover O i1 516103 A ee SEI 22 51091 X Filter Kleensweep inlet 2 required 23t 532701 Flodightbub 24 X 58091 Gasket lightbulb 1 perbub 25 532721 f Lightfixture with gasket 260 534560 A A4 Switch Snap 20amp 27 53301 Terminal strip 10 pole 28t 51901 f Solenoidvalve Standard and CSA 29t 5202522 Barbedfitting 1 4 tube x 410 32 30 520432 c f Adapter 1 4 tube x 1 8 MPT 90 Page 54 Empire Abrasive Equipment Company 51860 FootTradleAssemby 32 518661 A3 A Valv
6. 1 each end ose clamp 2 1 each end Pressure Vessel 6 c Pressure vessel assembly 1 cu ft Pressure vessel only 1 cu ft ProFormer 7 760739 Hopper 1 cubic foot ProFormer 8 524371 Gasket reclaimer to hopper 9 523942 Sealing ring rubber 2 1 8 ID 10 510431 Plunger sealing PVC coated 11 546072 Plunger guide 1 2 NPT x 3 1 2 nipple 12 19 maj 15 gt 316 17 18 Tee 1 x 1 x 1 2 NPT Check valve 1 NPT Ball valve 1 NPT Hose clamp for 1 ID hose 1 each end Hose 1 ID specify 1 5 for 1 cu ft 3 5 for 3 cu ft Tee 1 x 2 x 1 NPT Nipple 1 NPT x close HD Label WARNING Do not disassemble Label WARNING Flange above 7 10 11 12 13 14 15 16 17 18 9 Page 43 Empire Abrasive Equipment Company Sure Flo Media Regulators Part Number Catalog Name Description am 290383 Manual Manual Sure Flo Media Regulator grit valve 25 lbs normally open 9 clearance required 290215 Pam Automatic Sure Flo Media Regulator grit valve 30 Ibs normally closed 9 clearance required 290188 Conversion kit Converts Manual Sure Flo to Automatic 25 lbs ra 2 Z 2 S Manual Sure Flo Media Regulator Parts Item Dare Description Nozzle Grit Comments Number 525451 Metering tube 3 8 ID Small Fine Back out roller bolt 1 2 525782
7. For systems with large quantities of dust mixed with blast media all dust and media should be removed from the system and new media installed Step 8 If more than a small amount of media is found in the dust collector waste additional reclaimer tuning band adjustment may be required Follow Steps 9 through 13 Step 9 Adjust the tuning band back to the previous reference mark on the reclaimer body reducing the opening between the reclaimer and the band Step 10 After operating the blast system for at least one 1 hour turn the cabinet power switch OFF Inspect the dust drum waste for reusable media Step 11 If no media is found in the waste adjust the tuning band to expose 1 16 less reclaimer body slot area Step 12 Make a new reference mark on the reclaimer body Step 13 Repeat Steps 8 through 13 until a small amount of media is found in the dust collector waste Adjustment is complete The schematic diagrams in Figure 6 illustrate 1 the basic operation of the system 2 the air and media flow before and after blasting Page 17 Empire Abrasive Equipment Company Figure 6 Blast and Recovery Operation IMPORTANT An insufficient volume of secondary air entering the reclaimer will cause dust to accumulate with the good media in the storage hopper or pressure vessel This accumulation leads to inefficient blasting Conversely too much secondary air will cause useful media to
8. you now own equipment that will properly meet your blasting requirements You can select the proper media operating procedures and maintenance steps by following the recommendations in this manual If you need more information about any aspect of your machine s operation or the blasting process contact your local distributor or the factory The following measures will also help you improve the efficiency of your blasting operation Step 1 To accomplish more in less time use the largest nozzle practical for your operation Of course nozzle diameter may be limited by the amount of compressed air available but an increased volume of compressed air is often justified by reduced labor costs Also if you are blasting small parts it doesn t make sense to use a big nozzle as most of the blast pattern will be overspray Step 2 For faster cleaning use the highest pressure practical for your operation Maximum pressure for a given operation is limited by type of media e g glass beads can break down rapidly above a certain pressure and amount of material which must be removed from the workpiece Step 3 If you are blasting small parts it may be more efficient to manipulate the part with tow hands and use an optional fixed nozzle holder Step 4 Never underestimate the importance of clean dry air More operational problems are traceable to the lack of clean dry air than any other single factor If the supply air is not clean and dry med
9. 2 MPT 3 552222 Bolt 7 16 14 x 1 1 4 4 753092 Roller stop holder 5 551352 Screw 8 32 x 1 2 2 per assembly 6 753632 Pinch roller 2 per assembly 7 753292 Flange 2 MPT 8 552052 Bolt carriage 3 8 16 x 2 1 2 10 9 552762 Lock washer 3 8 ID 12 10 552542 Nut hex 3 8 16 8 11 552672 1 2 Jam nut 1 2 13 12 N A Not shown in drawing 13 N A Not shown in drawing 14 N A Not shown in drawing 15 551852 Bolt 3 8 16 x 1 1 4 2 Auto Sure Flo 16 552662 Nut extension 3 8 16 2 Auto Sure Flo 17 290217 Handle assembly 1 2 13 Automatic Sure Flo 18 753622 Handle only 1 2 13 19 551732 Set screw 1 2 13 x 1 2 nyloc 20 505802 Shaft handle 21 505822 Spring tensioner 22 753682 Spring enclosure 23 753112 Diaphragm cover 24 521081 Adapter 1 4 NPT x 1 4 Tube 25 753462 Plunger guide 26 561422 O ring kit includes 2 for guide amp 1 for plunger 27 505872 Plunger with O ring 28 552842 Washer 1 2 ID 29 525002 Gasket diaphragm 30 525012 Diaphragm 31 290296 Spring assembly includes item shown in Detail B 32 565452 Tag instructions Sure Flo Page 45 Empire Abrasive Equipment Company Y od 1 Spring amp Diaphragm Assembly Detail WARNING Never attempt to disassemble the spring assembly in the automatic Sure Flo The spring is under tension and could cause injury to personnel MG 78 Exhaust Valve Assembly amp Options Part
10. 2 1 Loading Media section 3 1 Suction System Media Flow Adjustment and section 3 3 Reclaimer Adjustment Pressure System Step 1 Turn the ProFormer system off Open the left side equipment access door and locate the reclaimer media storage hopper and pressure vessel Step 2 Adjust the T handle of the Sure Flo grit valve counter clockwise fully opening the regulator Close the 1 ball valve choke valve located on the pressure vessel pipe string assembly Fully open the reclaimer tuning band Step 3 Turn the ProFormer system on and open a part loading door Remove the pressure nozzle and nozzle washer from the end of the blast hose Place a container such as a bucket inside the blast cabinet Place the blast hose inside the container and close and latch the part loading doors Page 21 Empire Abrasive Equipment Company Step 4 Adjust the blast pressure regulator to 40 psi Insert each hand into a cabinet glove and grip the blast hose firmly Aim the hose into the container and press the foot treadle Blast for 30 seconds to remove all media from the blast hose Step 5 Turn the ProFormer system off Clean both reclaimer screens readjust the Sure Flo grit valve and close the reclaimer door Dispose of all waste properly Step 6 The system is ready for new media Refer to section 2 1 Loading Media section 3 2 Pressure system Media Flow Adjustment and section 3 3 Reclaimer Adjustment 4 4 Pneumatic Controls
11. See section 4 1 for Media Selection and Use The suction system hopper should be filled to the bottom of the reclaimer screen The pressure system vessel may be filled to the base of the sealing plunger Total media capacity by weight for the suction and pressure ProFormer system is shown for popular media in the table below Method 1 With the cabinet switch OFF media may be loaded through the removable reclaimer access door The reclaimer is located inside the left component access door After loading the media reinstall the reclaimer door and insure an airtight seal Method 2 With the snap switch ON and the dust collector running load media through the media load station inside the right cabinet door Place the appropriate quantity of media between the cabinet cone and media load station baffle The system will slowly add the new media Walnut Shells or Glass Beads Aluminum Oxide Steel Shot or Grit a Plastic Suction 10 Ib 15 Ib 25 lb 5 lb Pressure 75 lb 100 Ib 200 Ib 30 lb IMPORTANT Be careful not to overfill pressure systems Overfilling will cause malfunction and premature wear See section 5 1 Daily Maintenance CAUTION If your application requires aggressive media such as aluminum oxide garnet or steel grit it is recommended that you use optional heavy duty ducting reclaimer lining and DI CARB or BORON nozzles to prevent premature wear Empire strongly recommends using bor
12. The ProFormer system uses a patented pneumatic control circuit to protect workers workers environment and activate the blast Step 1 Turning the system snap switch on energizes the interlock solenoid valve permits air to enter the control air line to the foot treadle illuminates cabinet lights and start the fan motor Step 2 The operator steps on the foot treadle opening a three way control air valve Air enters the door interlock supply tubing continuing to the door air jets If the part load unload doors are closed latched and door air jets are sealed the control air lines pressurize and open the main blast air valve and the pressure systems exhaust valve to close The opening of the main air valve starts the blast Step 3 When the operator removes his foot from the foot treadle the three way air valve close shutting off air to the controls and exhausting all down stream air The control air line pressure bleeds from the door interlock supply tubing main blast air valve and the pressure system exhaust valve This permits the main blast air valve to close and the pressure system exhaust valve to open stopping the blast Step 4 When a part load unload door is opened the pad covering the door interlock air jet is unseated When the foot treadle is pressed with a door open control air bleeds from the door air jet opening preventing the control circuit from pressurizing The main blast air valve will not open and blasting wi
13. are occasions when blast pressure media and nozzle size requirements will not allow the Sure Flo Media Regulator to be properly adjusted to the desired media flow rate Refer to the tag attached to the regulator T handle for additional instructions and see section 4 0 Suggestions for Efficient Blasting for helpful hints Page 15 Empire Abrasive Equipment Company 3 3 Reclaimer Adjustment All ProFormer reclaimers can be adjusted to control the average size of media retained by the reclaimer The reclaimer is supplied with a tune able secondary air adjustment When the band is properly adjusted reusable media will be returned to the media storage hopper Unwanted dust and broken down media fines will be removed from the system and conveyed to the dust collector See Figure 6 Empire s reclaimer design has vertical slots with a solid tuning band The original ProFormer reclaimers have horizontal slots in both the reclaimer and tuning band Fine tuning adjustments of both reclaimers are similar Just remember to move the band in the direction of the reclaimer slots horizontal slots rotate the band vertical slots slide band up or down The tuning band is joined at both ends by a bolt and wing nut that must be loosened before the band can be adjusted The slot pattern around the reclaimer body has one slot omitted The joined ends of the tuning band must be located over the area of the omitted slot NOTE Dust collector
14. bit can be inserted into the nozzle to check its size Step 4 On suction systems check the air jet for wear Step 5 Loosen the set screw in the side of the gun body and remove the air jet See Figure 13 Figure 13 Air Jet Step 6 If the air jet shows wear rotate it 90 and reinsert it into the gun Step 7 Re tighten the set screw IMPORTANT If an air jet is allowed to wear completely through it will cause premature wear of the gun body and nozzle Step 8 Check the nozzle adapter and gun body for wear Replace if necessary Step 9 Check the window gaskets for leaks Replace if necessary Page 29 Empire Abrasive Equipment Company Step 10 Check your spare parts inventory Ensure that you have an adequate supply of replacement items 5 3 Storage or Temporary Non Use If your ProFormer system will not be used for several days or more follow these steps to remove media and prevent media from caking inside the system Step I e Suction systems Empty media from the cabinet and storage hopper To remove the media from the storage hopper remove the rubber plug from the bottom of the SAR 2 regulator e For pressure systems A Reduce blast pressure to 40 PSI B Close the choke ball valve on the pressure vessel pipe string See Figure 14 Figure 14 Closed Choke Valve Remove the blast nozzle and washer from the blast hose C Pressurize the vessel as if t
15. clear of the fan exhaust Step 5 Set the blast air pressure regulator to the desired pressure The blast pressure may be set as low as 20 psi but do not exceed 125 psi Step 6 Insert both hands into the cabinet gloves and firmly grasp the suction gun or pressure nozzle Step on the foot treadle The blast should start After a few seconds the airflow from the nozzle will stabilize Blast will stop when the foot treadle is released Step 7 If applicable press each dust collector pulse button once with the dust collector on to insure pulse function The optional Photohelic control pulsing of the dust collector filters is automatic Adjust both red needles to below zero psi The black needle must rise above both red needles to activate the pulse An increase in the gauge zero adjustment may be required to test this function After a successful test the gauge setpoints should be Page 11 Empire Abrasive Equipment Company set at a value of 2 psi for minimum and 4 psi for the maximum pressure When the system is off reset this gauge to zero Step 8 Turn the cabinet snap switch to the Off position The cabinet lights will extinguish and the dust collector fan will stop The ProFormer system is now ready for media loading and part processing 2 0 Equipment Operation 2 1 Loading Media There are two methods for loading media into the ProFormer system Always check the media level in the system before adding additional media
16. service life in an aggressive or high use environment These components are normally very cost effective because they reduce downtime repair interval and maintenance costs Extended wear components are sold individually so you can tailor features to your application needs and budget urethane coating surfaces by five times Reclaimer Ultra The Ultra Wear lining increases normal service life by a factor of Wear lining te n Di Carb Di Carb nozzles are for use with steel abrasives and glass beads tungsten carbide nozzles Boron carbide Boron carbide nozzles are for use with aluminum oxide silicon Nozzles carbide and garnet media Rubber curtains Cabinet life is increased with the use of rubber curtains Free hanging curtains are made of black 1 8 neoprene and held in place with rubber knobs for easy replacement These curtains actually last longer than steel White curtains are available to brighten the cabinet interior and it doesn t degrade with use as does white paint on steel Window Window protectors can be provided in clear plastic or as a protectors perforated screen to reduce frosting and pitting of the cabinet window Matting To pad parts and prolong the life of steel support surfaces mats are offered for turntable tops and cabinet floors Suction blast systems The fixed gun holder is adjustable to position any gun in any orientation so the operator can use both hands to manipulate work pieces in the blas
17. 0 3 440 480 60 3 550 600 60 3 2 Turntables Stationary or Tracks Available with Manual turntables facilitate the handling of heavy parts The turntable dolly travels on a track or is fixed inside the cabinet Most stationary designs feature a low profile that provides operators with easy over the top access and does not waste interior cabinet space Turntable size 24 diameter with standard capacities ranging from 300 to 1000 pounds Pressure blast systems incorporating Empire s automatic Sure Flo media regulator allow the operator to adjust the richness of the air to media mixture from the workstation at the front of the cabinet As a result dialing in the optimum air to media ratio for a particular job is greatly simplified To further assist the operator an indicator gauge displays relative media richness In applications where media is changed frequently or where contamination can cause periodic clogging of the media regulator a push button choke is available with fine tuning In applications such as shot peening in which very precise metering of media is required a fixed orifice media regulator is attached below the Sure Flo media regulator The low media level sensor and indicator warns the operator when the media supply in the pressure vessel is low The indicator sensor consists of an electronic probe in the vessel that activates a signal light mounted on the front of the cabinet Empire s extended wear components increase
18. 2 air jet 19 27 34 42 3 8 nozzle 3 16 air jet 29 39 50 62 7 16 nozzle 7 32 air jet 38 52 66 80 AIR REQUIREMENTS SCFM FOR PRESSURE BLAST 40 psi 60 psi 80 psi 100 psi 1 8 nozzle 10 14 17 20 3 16 nozzle 22 30 38 45 Ya nozzlet 41 54 68 81 Standard nozzle 1 3 4 blast hose option is recommended to reduce blast hose wear Step 3 Use the chart below as a guide to determine the size of the compressed air line needed for your ProFormer system Even when there is sufficient compressed air available the supply air line to the system must be large enough to prevent friction losses that create pressure drops which will reduce blast pressure and efficiency Step 4 The customer is to provide and install an air supply shut off valve This should be a three way valve that will bleed off all trapped down stream compressed air from the cabinet The valve must also be able to be locked when closed Line Size in Length of Air Line ft Air Volume SCFM Sa Up to 95 13 to 38 1 95 to 190 38 to 59 1 1 4 190 to 350 59 to 85 Page 10 Empire Abrasive Equipment Company 1 7 Earth Ground An Earth Ground stud is provided at the bottom right side on the enclosure back wall It is important to connect the ProFormer system to an Earth Ground to bleed off static electricity which may be generated while blasting The Earth Ground may also reduce the discomfort an operator may experience wh
19. 200 to G 16 G 80 S 390 S 110 Any Media Size 80 300 180 300 to to to to Size Mesh Mesh Mesh Mesh G 50 G 200 S 170 S 70 Suction R R R R NR R NR R R Pressure R R R R NR R NR R R R Recommended Recommended optional vibrating screen for mesh sizes 200 to 300 or when high humidity is a problem NR Not Recommended Recommended optional vibrating screen and aerated media regulator for mesh sizes 200 to 300 Spherical media such as glass beads are used for general purpose cleaning and finishing where a satin like finish is desired with little dimensional change Glass beads are effective when used with pressures in the 20 to 60 PSI range Above 60 PSI excessive bead breakdown will occur Angular aggressive media such as aluminum oxide steel grit and garnet generally provide faster cleaning and produce a less polished finish compared to glass beads Aluminum oxide and steel grit are suitable for use at pressures up to 100 PSI Garnet breaks down quickly at pressures greater than 40 PSI Walnut shells or plastic are sometimes used for delicate parts paint removal or when a polished finish is required Pressures from 20 to 100 PSI may be used with these media depending on the application When changing from one type of media to another clean the cabinet interior and media hoses thoroughly to avoid cross contamination Page 19 Empire Abrasive Equipment Company CAUTION If your app
20. Adjustments Clogged dust bag s Shake dust bag or dust collector bags Blinded filters reduced air flow due to age of the filters Over a period of years dust may penetrate the dust filter to the extent that normal air flow is restricted even when filters are pulsed regularly When this condition is reached replace the filters Fan rotation backwards Reverse the fan rotation Media has high dust content Replace media and adjust reclaimer tuning band Recovery hose blocked Remove hose inspect and remove obstruction Cabinet air inlet plugged Blow filter clean with air line Dust collector door leaks air Tighten door replace gasket if necessary Blast nozzle or air jet too large Replace worn nozzle with recommended size maximum Y diameter pressure maximum 7 32 air jet for suction Operating air pressure too high Decrease pressure to within recommended range Page 32 Empire Abrasive Equipment Company Problem No air or media flow from the nozzle Probable Cause Remedy Compressed air line shut off Open all air valves from compressor Cabinet Doors not tightly closed Close cabinet doors sealing door interlock Regulator adjusted to zero Adjust regulator Nozzle clogged Disassemble and clean nozzle Door interlock air hose leaking Replace hose If problem continues
21. DX a a DU Qe dp A i I MEN 54 10 0 Warranty iii e e d ee tu et ee ees 56 Page 4 Empire Abrasive Equipment Company Introduction Congratulations on your selection of the ProFormer Cabinet System from Empire Abrasive Equipment Company This manual is provided to assist you with the unpacking assembly use and maintenance of your ProFormer Cabinet System Please read this manual carefully and keep it in the handy plastic pouch attached to your system for future reference If you have any questions about the operation or maintenance of your equipment contact your Empire distributor Empire The leader in air blast technology Empire specializes in the design and manufacture of air blast equipment and has continued as an industry leader of more than 50 years Today Empire produces the most extensive line of air blast products in the world In addition to ProFormer systems our product line includes Pro Finish Cabinets ECON O FINISH Cabinets Modified Systems Automated Blast Systems Blast Rooms and SuperBlast Portable Blasters Empire Abrasive Equipment Company s reputation as a leader in air blast technology is the result of meeting our customer s demand for quality equipment and systems that deliver increased productivity We support our equipment with training service and testing programs When you need advice assistance or equipment on short notice our national network of distributors assures that help is nearby
22. Metering tube 1 2 ID Small Med Fine Med Back out roller 1 2 1 523592 Metering tube 3 4 ID Medium Medium Supplied as standard 523512 Metering tube 3 4 ID Medium Medium Use below 32 F red 525792 Metering tube 5 8 ID Med large Med coarse 525802 Metering tube 7 8 ID Large Coarse High production use 2 753692 Valve body 2 MPT 3 552222 Bolt 7 16 14 x 1 1 4 4 753092 Roller stop holder 5 551352 Screw 8 32 x 1 2 2 per assembly 6 753632 Pinch roller 2 per assembly 7 753292 Flange 2 MPT 8 552052 Bolt carriage 3 8 16 x 2 1 2 4 9 552762 Lock washer 3 8 ID 6 10 552542 Nut hex 3 8 16 6 11 552672 1 2 Jam nut 12 551902 Bolt hex 3 8 16 x 3 2 13 753372 Adapter manual body Sure Flo 14 290384 Handle assembly 1 2 13x 4 Page 44 Empire Abrasive Equipment Company Automatic Sure Flo Media Regulator Parts Item net Description Nozzle Grit Comments Number 525451 Metering tube 3 8 ID Small Fine Back out roller bolt 1 2 525782 Metering tube 1 2 ID Small Med Fine Med Back out roller bolt 1 2 1 523592 Metering tube 3 4 ID Medium Medium Supplied as standard 523512 Metering tube 3 4 ID Medium Medium Use below 32 F red 525792 Metering tube 5 8 ID Med large Med coarse 525802 Metering tube 7 8 ID Large Coarse High production use 2 753692 Valve body
23. Operating Instructions for the ProFormer Cabinet System Pressure and Suction s ABRASIVE EQUIPMENT 2101 West Cabot Boulevard Langhorne PA 19047 1893 www empire airblast com Empire Abrasive Equipment Company Model Number Serial Number Date of Purchase Date of Installation Distributor Purchased From Name Address Phone kok Kk Manufactured by EMPIRE ABRASIVE EQUIPMENT COMPANY 2101 West Cabot Boulevard Langhorne PA 19047 1893 Phone 215 752 8800 Fax 215 752 9373 Empire equipment should be properly maintained per the operating instructions For peak performance of your equipment use only genuine Empire replacement parts accept no substitutes The use of non Empire parts will void the warranty PARTS AND SERVICE 1 800 497 4543 To order Empire replacement parts contact your local authorized Empire distributor For the name of your local distributor call Empire Customer Service 1 800 497 4543 or fax us at 215 752 9373 or e mail us on our website www empire airblast com and we will call you back CAUTION Never use silica based abrasives in Empire blast systems Page 2 Empire Abrasive Equipment Company Operating Instructions for the ProFormer Cabinet System Suction and Pressure Empire Abrasive Equipment Company 10 06 06 Page 3 Empire Abrasive Equipment Company Table of Contents Table of Contents Zoe a pa ta ia nav ordena je as a Gra a rt
24. RepairKitforl Aquamati 4 550232 550232 Gauge 550232 1 4 NPT 550212 1 8 NPT back mount 6 523155 Mounting Feet Quick Clamp 522157 Porting Block 8 52022 Hose adapter 1 4 x 1 4 QuikClmp 2 O Pid Adapter 543542 Elbow 1 NPTstreetC C CSC idC 505782 Coupling 1 FPT UF 100 9 522154 A 10 522156 pp BEA meso RAP TITA 15 520432 Adapter 1 4 Tube x 1 4 NPT 90 16 544497 Bushing 1 x 1 2 Brass 17 543583 Elbow 1 2 x 90 18 520362 HoseBarb 1 2 gt Repair kit P N 517583 includes the seal kit P N 517582 O Ring for modular pipe strings P N 522162 Page 53 Empire Abrasive Equipment Company 9 8 Basic Cabinet Assembly Components e e INN Sizes 1 510401 CCC Safety Glass 14 x 22 2t 524480 Gasket window 6 section pos Rf ERE ou 9528581 Gasket window frame per ft 6 required 4 951461 J A 4 3 Knob 3 8 16 4 required 5 55182 Bolt 3 8 16 x 1 1 4 4 required 6 52591 Spacer window 4 required 7 14004 Cd Window Kit items 1 through 6 a 509891 m so Gloves opui
25. Silencer optional Page 51 Empire Abrasive Equipment Company 9 6 Ducting Hoses ET Conveying Hose Standard Systems Suction or Pressure with Reclaimer amp Collector Installed Upgrade 522351 Standard Duty Conveying Hose w o clamps um EP eng 140354 140338 Heavy Duty Conveying Hose w clamps D diens Dust Hose Item Part Number 6 x 31 I D x length Clamps and Adapters Item Part Number 1 Descripton Hose clamp Standard Duty conveying hose 5 Hose clamp Heavy Duty conveying hose Nominal hose diameter 520551 Hose clamp dust hose Nominal hose diameter Note 2 hose clamps are required per hose Page 52 Empire Abrasive Equipment Company 9 7 Pipe Strings Pipe String Assemblies Part Number Pipe String Size sed With 140279 140280 Pressure FaStrip Pipe String Mounting Hardware Ss i M y RJA A A3 mama 7 P i Fi EET T 6 poU m de JER pile i 2 Pe o 4 8 J 1 1 2 Pipe String 1 Pipe String Components Air Filter 1 2 manual 1 manual Norgren 1 Element for Norgren air filter SH O ring and gasket kit for Norgren air filter 2 PS SRI Air Pressure Regulator Norgren Diaphragm amp O ring kit for Norgren regulator 517042 2 MainAirValve l Aquamati 3 517582 Diaphragm and seal kit for1 Aquamatic 518512 jSpecialwrenchforl Aquamatic 51758
26. a taka mia rdg 4 Introduction veo hU i A Davus a ea D ta ety UA daj et A 5 1 0 Installation it a ob en aa op Goga a aaa etur edebat 6 Ll Hand Tools Required eee uto totae a To CT e e Od a a 6 1 2 Preparing for Installati n s OA RUIN P TORIO prO AUG RAE KD iia 6 1 9 G tting Started tiei de Db aa denied Ped dad Oleo ba ai bal Do daten ea rains A a P dd 6 1 4 Positioning the ProFormer System 6 1 5 Electricat Connections ose tyi eid pa bao usadnika asd dado 7 1 6 Compressed Air Connection avisa PST TOT Fer o E e reta en eines 10 Lo Earth Ground ane ries tarte M videi Das A P edebat dava etm 11 1 8 Installation Checa a japi a ERR p Ek E TAREA AF een 11 2 0 Equipment Operation oo ovo Valse eade ensi Saa ese a OI dH NT pe RR MO S 12 2 1 Loading MEJA zova dop a ras ER 12 2 2 Start U Pr ssa ca adeo da Wile de SA ea Ne AA 13 23 BD iii mem emae mo 13 2 4 Dust Collector Cartridge Cleanthes ds 14 2 9 Edquipineht Sh t DOWEL ua TA dd iau ea ean PEEL xd dd Sika 14 3 0 Equipment Adjustments ee 15 3 1 Suction System Media Flow Adjustment droit dada IS 3 2 Pressure System Media Flow Adjustment ere eR Sebe koi a 15 5 9 Reclaimer AdJUSL BEL dva dete ni epp duende NDA Sae ji Re te a uU icd ode 16 4 0 Suggestions for Efficient Blasting 19 4 1 Media selection and Use use tp in tried d qaia ii 19 4 2 Bist PALE TA az SS PN A PR tps ni etr Dat debe oi dde P eas
27. a regulator closed Adjust media regulator Pressure System Leaking sealing plunger and or exhaust valve Check for compressed air leaks and repair Pressure System Sure Flo media regulator obstructed Open Sure Flo media regulator to full open close the choke valve remove blast nozzle set blast pressure at 70 80 PSIG and attempt to blast All air will be forced through the media regulator clearing the obstruction If media flow problems persist shut off and lock out compressed air supply disassemble media regulator and clear obstruction Page 34 Empire Abrasive Equipment Company 6 2 Troubleshooting the Pneumatic Control Circuit Hand Tools Required The following tools are required to troubleshoot the pneumatic control circuit e Pressure tester P N 140382 e 7 16 open end wrench e Flat blade screwdriver Step by Step Procedures Refer to the control circuits shown in Figures 15 and 16 and the troubleshooting procedures listed on the pages that follow e a a o TON i FN git 2 paf N v A s Figure 15 Pneumatic Circuit Suction e all o P Tos RY B gt P4 4 UV y Figure 16 Pneumatic Circuit Pressure Page 35 Empire Abrasive Equipment Company Problem Switch is on The lights and dust collector motor work but blast will not activate Probable Cause Test Remedy Step 1 Confirm that the If
28. aon diea i a 20 43 Changing the Med agi e ode lao Sd 21 4 4 Pneumatic CONOS ce costa et e er Fre cu a tee eda a Pe ee Cd a dele 22 4 5 Helpful Hints for More Efficient Blasting os asi ka das e On Qe TA 27 4 6 Cartridge Dust Collector Model SEM o ana M o phe A 27 5 0 Maintenance aa ka ja e A A SA ARREST X TRA a ERE GH a aSa 28 5 1 Daily Maintenance dei ness oa opted ja wed e Mey vedi d ea ge 28 5 2 Weekly Maintenance i sc koki e OW A o a ERGO A Fed e vertes HR 29 5 3 Storage or Temporary Non USE e ee ee ememememe meme e nennen 30 6 0 Troubleshooting oiueiai etn AA RR d ira A CR QU Yale a AE vidna 32 6 1 Troubleshooting NATU gave ato i RATEN Equi Wists das A AI 32 6 2 Troubleshooting the Pneumatic Control Circuit 35 7 0 Recommended Spare Parts 38 8 0 Options and ACCESSORIES eese e deed eiua aa e RR REA E PROCU Qa RAS RR RR taeda 39 9 0 ProFormer M Parts uo nepre NE PE ERE RES eed da 41 9 1 REG LANNE IS O GH a SA AA 41 9 2 Pressure Blast Systems e daa a ER ER ee 42 9 3 Suction Blast Systems ri nas ido bana da sava ido esie aaa EM Ada AK 48 9 4 Dust Colector AAA eS 50 9 5 Blowers Pan amp Motor ccie ies iaai ti il 51 O O D cting HOUSES adio var dvd toC tuia AAA ER i AE nea ara 52 9 7 Pipe SITES A tor dt exero ANE ABK qe AAA Ne aep dE RE aes oe 53 96 Basic Cabinet Asset bly evt HS Or DR
29. be carried to the dust collector and be wasted To avoid these conditions adjust the tuning band to meet your specific blasting requirements When your system is new it will be necessary to readjust the tuning band periodically until the filters are seasoned Page 18 Empire Abrasive Equipment Company 4 0 Suggestions for Efficient Blasting 4 1 Media Selection and Use Proper media selection strongly influences the efficiency of your blasting operation Your choice of media depends on the kind of job to be done cleaning deburring smoothing sharp edges paint removal preparation for coatings etc The size of the media depends on the results you need Fine media results in more impacts per second over a given area Therefore fine media is preferred for easy blasting jobs such as the removal of light rust from steel Large media results in fewer impacts but each impact has more force so that large media is more suitable for difficult jobs such as removal of mill scale Sometimes large and find media may be combined for optimum results The chart below lists the range of media recommended for each ProFormer Blast System Certain media such as sand and slag are not to be used in ProFormer cabinets both for health reasons and because they pulverize on impact and cannot be recirculated a 3 Walnut Aluminum Oxide Shells Media Type or Glass Beads Steel Grit Steel Shot mE Garnet n Plastic 46 to 100 to 25 to
30. e Listen and feel for air leaking at each door interlock air jet If leaking the cabinet access door must be closed tightly so that the air jets are sealed air tight Check and replace worn or damaged urethane bumpers in the doors If the door interlock air jets are sealed with no leaks go to Step 6 Step 6 Disconnect the control If the gauge is reading the line The control tubing tubing at the pipe string supply pressure go to Step 7 is leaking air valve Install a If the gauge reading is not the line pressure gauge on the supply pressure go to Step 8 open end of the tubing and step on the foot treadle The gauge should indicate the line supply pressure to the system Step 7 Reconnect the control If the gauge is reading below the line The blast air valve is defective tubing at the pipe string air valve Install a pressure gauge on the control line and step on the foot treadle Observe the gauge pressure supply pressure the blast air valve diaphragm has failed Repair or replace the air valve Page 36 Empire Abrasive Equipment Company Check the vent in the blast air valve diaphragm cover spring retainer nut for leaking air Confirms that the blast air valve diaphragm has failed Repair or replace the air valve Step 8 There are media problems Improper media See section 4 1 Media Selection and Use Improper media flow See
31. e hopper will transfer into the pressure vessel PA JE Figure 10 During Blasting Page 25 Empire Abrasive Equipment Company Thus you can determine the amount of media in the vessel in either of two ways 1 note how much continuous blast time you can achieve with a fully charged vessel and compare this with your current continuous blast time or 2 stop blasting open the reclaimer door and visually determine the media level by looking into the top of the vessel F E Figure 11 After Blasting Overfilling pressure vessels will cause improper operation and premature wear Allow sufficient time after blasting for the pressure vessel to refill 2 minutes When the pressure vessel is filled check to see if any media has remained in the storage hopper indicating that the vessel is overfilled the sealing plunger may not seat tightly when you start blasting See section 5 3 Storage or Temporary Non Use for instructions on how to empty the pressure vessel Refer to section 2 1 Loading Media for instructions to add media Figure 12 Pressure Vessel Overfilled Page 26 Empire Abrasive Equipment Company 4 5 Helpful Hints for More Efficient Blasting The efficiency of your blasting operation depends on four factors 1 Equipment selection 2 Media selection 3 Operating procedures 4 Maintenance With the help of your Empire Distributor and or Empire factory representative
32. e is controlled by how far the media hose is inserted into the regulator For normal operation approximately of the air inlet port is blocked by the media hose This may vary slightly when changing media size nozzle size and or blast pressure To find a uniform media flow loosen the thumbscrew and slide the media hose into the SAR 2 regulator to increase and withdraw the hose to decrease media flow at the nozzle To determine if media is flowing look through the media regulator air inlet while the gun is operating Listen for the sound of the blast to be smooth and constant 3 2 Pressure System Media Flow Adjustment The ProFormer pressure blast system is supplied with the patented Sure Flo Media Regulator which is installed at the bottom discharge port of the pressure vessel By rotating the T handle media flow through the regulator and out of the blast nozzle may be adjusted Step 1 Rotate the T handle counter clockwise until there is no resistance Reverse direction and make three full turns of the handle Step 2 As the T handle is turned clockwise the media flow through the regulator will be reduced While the system is blasting make final adjustments in turn turn or 1 8 turn increments IMPORTANT Optimum and most efficient blast is when the media exiting the blast nozzle is just visible Sure Flo Media Regulator adjustment may vary slightly when media size nozzle size and or blast pressure is changed There
33. eforFootTreade 33 518071 Repair Kit For Treadle Valve 34 52260 2 Hose Assembly 7 for Foot Treadle 35 09821 gt o Gun dasto y O 36 gt 0 52201 522641 Hose with fittings dust off gun 37 528951 QGrommet dustoffhose 1 4 5 8 x 7 8 gg 52391 QGrommet blast hose 1 x1 3 8 523901 Grommet suction air hose 3 4 x 1 1 16 30 53691 A4 L ole Seal 40 760697 760698 Floor section std cabinet 2 required o o o jp 551742 551742 Leveling bolt 3 8 16 x 2 4 required 42 43 44 i 45 46 47 48 strip reclaimer mount 49 140280 Piping Assembly 1 F gt L i 2 Hi 2 Filter SEM 2 2 required Pressure Vessel Assembly R D Pipi 140279 Piping Assembly Y 140312 Blower Assembly 1 1 2 HP 230V 60Hz 1 Ph 52 53 54 Recommended spare part consumable wear item t Essential component to prevent downtime tt For systems with optional equipment Specify length per foot gl o 32t 33 54 55 36 RE 39 40 poga BEE HE 45 46 47 REM D i Decal Empire logo Decal orange dot strip 42 Rubber nut 1 4 20 for optional curtains n WARNING Replace the window with Empire safety glass only Fail
34. en static electricity is discharged The Earth Ground conductors may be insulated or bare Note that defects are more easily detected during visual inspections of bare conductors The minimum wire size is dictated by mechanical strength rather than current carrying capacity Flexible conductors should be used when frequent connecting and disconnecting of the Earth Ground is anticipated 1 8 Installation Check Step 1 Check that all pipe and hose connections are tightly fastened and air tight Check that all safety pins are properly installed in all quick couplings Step 2 Check that all electrical box covers are securely installed Turn on the plant compressed air supply to the system Step 3 Check that the dust drum under the dust collector has been installed properly It must be sitting squarely on the dust drum platform and centered under the cover Set the dust collector pulse pressure regulator to 40 psi Check that the optional fan silencer is fully opened Step 4 Turn the cabinet snap switch to the On position The cabinet lights will illuminate and the dust collector fan will start Check that the fan is rotating in the correct direction CAUTION Disable and lock out power sources before performing service or maintenance work Do not look into the fan outlet to determine the correct motor rotation Check that the fan exhaust is clear of tools and free of debris before checking fan rotation To avoid personal injury stay
35. erior thoroughly to avoid contamination of the new media IMPORTANT Always use proper safety and protective equipment when disposing of collector waste Dispose of this waste properly Suction System Step 1 Turn the ProFormer system off Open the left side equipment access door and locate the reclaimer media storage hopper and SAR 2 media regulator Step 2 Using proper safety and protective equipment place a container such as a bucket directly under the storage hopper and SAR 2 regulator Loosen do not remove the 7 16 nut at the bottom of the regulator plug Pull down on the plug removing it from the regulator This will allow the media to empty from the storage hopper into the container Step 3 Turn the ProFormer system on Close and latch the part loading doors Insert each hand into a cabinet glove and grip the suction gun firmly Aim the nozzle toward the back of the blast cabinet and press the foot treadle Blast for 30 seconds to remove all media from the suction hose and gun assembly Step 4 Release the foot treadle Using proper safety and protective equipment open one of the part loading doors and use the Blowoff gun to remove the media from ledges and surfaces into the cone for recovery Step 5 Turn the ProFormer system off Clean both reclaimer screens reinstall the SAR 2 drain plug and close the reclaimer door Dispose of all waste properly Step 6 The system is ready for new media Refer to section
36. ia quickly becomes contaminated causing flow problems which wastes media and leads to excessive operator downtime 4 6 Cartridge Dust Collector Model SEM 2 Additional information about the operation of the ProFormer Cartridge Dust Collector can be found in the collector Installation and Operation Manual This manual can be found inside the left maintenance access door in an envelope attached to the inside left rear wall of the system Page 27 Empire Abrasive Equipment Company 5 0 Maintenance 5 1 Daily Maintenance Step 1 Turn the cabinet snap switch on Step 2 Remove the accumulated dust from the dust collector drum and the debris from the reclaimer screen Step 3 Check the condition of the media If the media is contaminated or broken down into dust thoroughly clean the inside of the cabinet and recovery system and reload with new media See section 2 7 Loading Media Step 4 Adjust the reclaimer tuning band if you observe a dusty condition when blasting See section 3 3 Reclaimer Adjustment Step 5 Check the media level For optimal operation the media level should not drop below one half the recommended capacity A The media level in suction systems can be observed in the media storage hopper B The media level in pressure systems can be observed by looking through the optional sight glasses or the reclaimer door down into the top of the vessel When the vessel is de pressurized the sealing plunger must be vis
37. ible Add media until just visible below the sealing plunger Step 6 Check light bulbs and gloves Replace as reguired Step 7 Open the manual drain on the general purpose filter in the cabinet pipe string and drain any accumulated moisture and oil Close the drain and dispose of the waste properly Step 8 All quick coupling connections must be equipped with safety pins Inspect all couplings and blast hoses daily for splits bubbles soft spots etc Screws should be flush with coupling surfaces Tighten screws if necessary Page 28 Empire Abrasive Equipment Company 5 2 Weekly Maintenance CAUTION If your application requires aggressive media such as aluminum oxide garnet or steel grit it is recommended that you use optional heavy duty ducting reclaimer lining and DI CARB or BORON nozzles to prevent premature wear Empire strongly recommends using boron carbide nozzles when blasting with Aluminum oxide which is the most abrasive media If these options are not included with your system they can be added Optional Rubber curtains for interior cabinet surfaces are also available Consult your Empire distributor for details Step 1 Repeat the daily maintenance procedures Step 2 Inspect all media carrying hoses for wear by feeling along the length of the hose for soft spots Hoses with soft spots should be replaced Step 3 Check the nozzle for wear When the nozzle is worn 1 8 oversize replace it A drill
38. lication requires aggressive media such as aluminum oxide garnet or steel grit it is recommended that you use optional heavy duty ducting reclaimer lining and DI CARB or BORON nozzles to prevent premature wear Empire strongly recommends using boron carbide nozzles when blasting with Aluminum oxide which is the most abrasive media If these options are not included with your system they can be added Optional Rubber curtains for interior cabinet surfaces are also available Consult your Empire distributor for details 4 2 Blast Pattern The size of the effective blasting pattern varies with the size type and length of the nozzle blast air pressure and the nature of the work piece Use the following chart and diagram as a guide but be aware that the approximate pattern diameters can only be determined by considering each case individually Figure 7 Blast Pattern Blast Pattern Diameter at Distance Listed Nozzle ID A B C Ya Y 11 4 Suction Blast 5 16 1 1 7 16 11 8 1 3 4 ki 1 8 Y 1 Y 2 Ys Pressure Blast 3 16 1 1 2 3 8 Va 11 8 1 21 2 Suction Blast at a distance of greater than 12 is usually not effective Page 20 Empire Abrasive Equipment Company 4 3 Changing the Media When changing from one type or size of media to another it can be extremely important to clean out the blast and recovery hoses storage hopper pressure vessel and the cabinet int
39. ll not occur Page 22 Empire Abrasive Equipment Company The following schematic diagrams illustrate the pneumatic control circuits for suction systems Figure 8A and pressure systems Figures 8B For each system type the cabinets are shown in blasting and non blasting modes shaded pipe is pressurized Figure 8A Page 23 Empire Abrasive Equipment Company Figure 8B Page 24 Empire Abrasive Equipment Company The following drawings show media flow through a typical pressure system and are provided to help you understand how to maintain the media at the proper level Pictured at right is a fully charged system with the vessel depressurized no blasting Note that the media fills the pressure vessel but that there is not media in the storage hopper Figure 9 Before Blasting When blasting starts the vessel pressurizes the media impacts the part being blasted and reusable media is recovered and accumulates in the storage hopper Continuous blasting time is limited by the type and amount of abrasive in the in the vessel when blasting starts normally 8 to 15 minutes with a fully charged 1 cubic foot vessel depending on nozzle size and blast air pressure Each time the operator stops blasting the vessel de pressurizes and the sealing plunger drops Media in the storage hopper flows into the vessel If blasting is stopped long enough usually 1 2 minutes all media in the storag
40. o blast These steps will cause the media to flow from the open end of the blast hose in a controlled manner The media can now be directed into a suitable container or receptacle After the pressure vessel is empty D Open the choke valve Page 30 Empire Abrasive Equipment Company E Replace the nozzle washer and nozzle F Return the blast pressure setting to normal Step 2 Drain the general purpose filter Close the drain valve Page 31 Empire Abrasive Equipment Company 6 0 Troubleshooting 6 1 Troubleshooting Chart Problem Good media is being carried to the dust collector Probable Cause Remedy New filters Continue use until filter cake forms approximately eight hours of operation Tuning band is open too far Adjust tuning band Insufficient media in suction hopper allows secondary air to enter Add media to recommended media level Media too fine Use more coarse media Pressure systems Worn plunger or sealing ring leaking air into reclaimer Replace plunger and or sealing ring Problem Media is escaping into the work area from the dust collector Probable Cause Remedy Hole in dust filter s or loose filter s Replace leaking filter s or refasten filter s Problem Poor visibility during blasting Probable Cause Remedy Reclaimer not adjusted properly Adjust reclaimer air inlet settings See section 3 0 Equipment
41. on carbide nozzles when blasting with Aluminum oxide which is the most abrasive media If these options are not included with your system they can be added Optional Rubber curtains for interior cabinet surfaces are also available Consult your Empire distributor for details Page 12 Empire Abrasive Equipment Company 2 2 Start Up Step 1 Check that all pipe and hose connections are tightly fastened and air tight Check that all safety pins are properly installed in all quick couplings Step 2 Perform maintenance checks per section 5 0 Maintenance Step 3 Check that the dust drum under the dust collector is empty and has been installed properly It must be sitting squarely on the dust drum platform and centered under the cover The dust drum and cover must create an air tight seal Step 4 Turn on the plant compressed air supply Turn the cabinet snap switch to the On position The cabinet lights will illuminate and the dust collector fan will start Step 5 Place the parts to be blast treated inside the blast cabinet The parts must be free of oil grease and moisture Close and latch the cabinet load doors Step 6 Set the blast air pressure regulator to the desired pressure Recommended blast pressure ranges for various media types are listed in the table in section 4 1 Media Selection and Use Do not exceed 125 psi blast pressure 2 3 Blasting Step 1 Insert each hand into a cabinet glove and grip the suction gun or
42. plied by Empire are not covered Commercial components are warranted under term of the original manufacturer Page 56
43. pressure nozzle assembly firmly Aim the nozzle at the part to be blast treated Step 2 Step on the foot treadle to start the blast After a few seconds the abrasive flow will stabilize and you will be ready for blasting Step 3 Do not pump the foot treadle It will decrease blast efficiency and cause premature wear of system components Step 4 Hold the gun or nozzle at a 90 degree angle to the part at a distance that produces the fastest results This distance may vary from 3 to 18 inches depending on the work piece and the desired finish See section 4 2 Blast Pattern Step 5 During the blasting process periodically check the Minihelic pressure gauge located above and to the right of the cabinet window This gauge indicates the condition of the filters If the gauge pressure is 4 psi or greater clean the filters as outlined in section 2 4 Dust Collector Cartridge Cleaning Step 6 The reclaimer screen will require periodic cleaning The frequency of cleaning will depend on the volume of debris produced Step 7 For pressure systems all the media in the pressure vessel will be used up after an extended period of blasting The operator must release the foot treadle to stop the blast and depressurize the vessel After a wait of approximately 2 minutes media will fill the pressure vessel and blasting can resume Step 8 When blasting of the part is complete blast additional parts or follow the instructions in section 2 5 Equipment Shu
44. ressed air and ambient humidity Install Empire Anti Static Strap part 510411 Problem There is blast air flow but intermittent or no media flow Probable Cause Remedy Blast air pressure too low Adjust and maintain pressure within recommended range Clogged nozzle Disassemble and clean nozzle Page 33 Empire Abrasive Equipment Company Damp media If media stays formed in a ball after squeezed in the palm of the hand it is too damp to flow properly Remove damp media from system and replace with new dry media Check compressed air supply filters Do not blast wet or oily parts Suction System Improper air jet nozzle combination Nozzle orifice size must be twice the air jet orifice size 1 8 diameter air jet requires minimum diameter nozzle Suction System Media hose improperly installed Adjust media hose in media regulator Check media hose at entry to the suction gun body hose clamp nut o ring and hose must create an air tight seal Suction System Clogged media hose Remove media hose from media regulator at the bottom to the media storage hopper bring that end of the hose through an open door and into the cabinet Remove the nozzle from the suction gun insert the blow off gun nozzle in the open end of the media hose and blow accumulated media and or debris out through the suction gun Pressure System Sure Flo medi
45. ron carbide upgrade for restrictor kit factory installed extended wear 18 552952 Washer steel 19 524062 Washer nozzle NW 1 1 ID x 1 1 2 OD x 1 4 thick pack of 10 20 524082 Washer nozzle NW 4 3 4 ID x 1 1 2 OD x 1 4 thick pack of 10 Page 47 Empire Abrasive Equipment Company 9 3 Suction Blast Systems Components Part ma 760751 opper 1 gun suction 546332 ipple 1 1 4 NPT x 3 5 H 2 N B Blast amp Air Hoses Buk 3622 4652 Description 1 52281 522851 Air hose assembly 1 2 ID 8208001 jo As 172 TD 7 5 B I 1 A 8 Air hose length std cabinet o 522581 522591 last hose section 5 8 I 520802 gt Blast hose 5 8 ID AS A y X Blast hose length std cabinet Page 48 Empire Abrasive Equipment Company SAR 2 Media Regulator Item Part Number 9 290156 SAR 2 Media Regulator complete 1 1 4 FPT 753351 Regulator body SAR 2 510121 Plug clean out 551042 Thumb screw 1 4 20 x 1 PARTS for MH 2 Guns Item Part Number Description Gun body MH 2 LONG handle Gun body MH 2 SHORT handle Air jet 3 32 orange Air jet 1 8 yellow Air jet 5 32 green Air jet 3 16 blue Air jet 7 32 white Air jet 1 4 red 6 526171 Sleeve rubber for airjet o Nozzle adapter plastic standard Noz
46. s a precaution clean the system and empty the dust collector often Change media that has excessive dust concentration Emptying the Dust Collector Always wear an appropriate dust mask when emptying the dust collector and changing filters Empty the dust collector daily 2 5 Equipment Shut Down Step 1 Release the foot treadle The blast will stop Remove the blast treated parts from the blast cabinet Step 2 Check the Minihelic pressure gauge for the condition of the duct collector filters If the gauge pressure is 4 psi or greater the filters must be cleaned Press and release one pushbutton which will clean one of the cartridges Wait 10 seconds Press and release the other pushbutton which will clean the other cartridge Continue this process alternating pushbuttons until the pressure is reduced to 2 psi Step 3 Turn the cabinet snap switch to the Off position Empty the dust collector waste drum Replace the drum squarely on the dust drum platform and centered under the cover The dust drum and cover must create an air tight seal Page 14 Empire Abrasive Equipment Company 3 0 Equipment Adjustments 3 1 Suction System Media Flow Adjustment The ProFormer suction blast system is equipped with the SAR 2 media regulator to control the flow of media to the suction blast gun The regulator is located at the bottom of the storage hopper assembly inside the left component access door The amount of media entering the hos
47. s require a coating of dust on the filter cartridges to achieve maximum filter efficiency also known as seasoning The filters are seasoned when the static pressure reading on the collector gauge is 2 or greater Step 1 Start with no reclaimer slots visible Adjust the band in one direction until 1 16 of opening is created between the band and reclaimer slots HELPFUL HINT Place a reference pencil mark on reclaimer body and a corresponding reference mark on the tuning band if horizontal slots Step 2 Operate the blast system for at least one hour Step 3 Turn the cabinet snap switch to OFF Step 4 Inspect the dust collector waste drum for reusable media Step 5 If no media is found in the waste adjust the tuning band to expose 1 16 more reclaimer body slot area Step 6 Make a new reference mark on the reclaimer body Step 7 Repeat Steps 2 through 7 until a small amount of media is found in the dust collector waste Adjustment is complete Page 16 Empire Abrasive Equipment Company NOTE As a new system is used the filters become coated with dust seasoned and the airflow in the recovery system will decease to the normal operating rate This will affect previous reclaimer tuning band adjustments If visibility becomes poor inside the cabinet when blasting there is too much dust mixed with the blast media The reclaimer tuning band should be re adjusted Follow Step 2 though 7 NOTE
48. section 3 0 Equipment Adjustment Problem There is excessive delay between stepping on the foot treadle and the blast activation Normally this delay should be between and 1 second for suction systems and 1 to 2 seconds for pressure systems Probable Cause Test Remedy Step 1 Restricted flow in control lines Disconnect the control tubing at the pipe string air valve Install a pressure gauge on the open end of the tubing and step on the foot treadle The gauge slowly reaches the full line supply pressure Check for kinks or crimps in the control air lines Step 2 Leak in control lines Disconnect the control tubing at the pipe string air valve Install a pressure gauge on the open end of the tubing and step on the foot treadle The gauge never reaches the full line supply pressure Trace leaks by moving the gauge up stream until the full line pressure is observed For pressure systems only if the gauge at the exhaust valve pressurizes rapidly to full line pressure the exhaust valve has a leak or a ruptured diaphragm Page 37 Empire Abrasive Equipment Company 7 0 Recommended Spare Parts The following chart lists the parts you should maintain in inventory to ensure continuous operation of your ProFormer system Qty Part No Description Pressure Suction 501331 Ya Di carb nozzle s
49. supply wire the system as shown in Figure 5 Use the adjacent tables for the approximate current draw in amps for the voltage of your system SINGLE PHASE SINGLE SOURCE SOURCE MOTOR CURRENT 110 120V 60HZ 1 HP 23 0A 220 240V 60HZ 1 HP 13 0A 220 240V 50HZ 1 HP 15 0A THREE PHASE SINGLE SOURCE SOURCE MOTOR CURRENT 208V 60HZ 1 HP 9 3A 220 240V 60HZ 1 HP 8 1A 440 480V 60HZ 1 HP 4 0A 550 600V 60HZ 1 Y HP 3 2A 380V 50HZ 1 Y HP 3 9A THREE PHASE amp SINGLE PHASE DUAL SOURCE SOURCE MOTOR CURRENT 208V 60HZ 1 HP 6 9A 220 240V 60HZ 1 HP 6 0 A 440 480V 60HZ 1 HP 3 0 A 550 600V 60HZ 1 HP 2 4A 380V 50HZ 1 HP 2 6A The approximate single phase current draw for all dual source systems is 3 amps at 110 120 VAC Page 7 Empire Abrasive Equipment Company Figure 2 Electrical Connection Locations The three phase schematic shown in Figure 5 also appears on the back of the transformer contactor electrical box cover The 10 foot 4 wire line cord is located above the cabinet light box The single phase schematic shown in Figure 4 also appears on the back of the light box cover Figure 3 Single Phase Terminal Board Access For Canadian CSA approved single phase cabinets remove the four screws from the cabinet light box cover Move the cover to the side and pull the attached terminal board plate from
50. t Down to shut the system down Page 13 Empire Abrasive Equipment Company 2 4 Dust Collector Cartridge Cleaning IMPORTANT Never pulse clean the filters when the system is off If dust is visible exiting the dust collector fan housing stop blasting and service the collector Pushbutton Control During the blasting process periodically check the Minihelic pressure gauge located above and to the right of the cabinet window This gauge indicates the condition of the filters If the gauge pressure is 4 psi or greater the filters must be cleaned Press and release one pushbutton which will clean one of the cartridges Wait 10 seconds Press and release the other pushbutton which will clean the other cartridge Continue this process alternating pushbuttons until the pressure is reduced to 2 psi Photohelic Control Option This option pulse cleans the dust collector filters automatically when they need cleaning The gauge high limit red needle must be set at 4 psi as the maximum operating limit The gauge low limit red needle must be set at 2 psi as the minimum operating limit The pulse pressure must be set at 40 psi IMPORTANT Always use proper safety and protective equipment when disposing of collector waste Dispose of this waste properly WARNINGS Explosive Dust Explosive dust is generated from blast media removed coatings and substrates An extreme concentration of dust may combust if ignited by spark or flame A
51. t collector on the right hand side There must be adequate space for work pieces to be easily loaded and unloaded through the cabinet doors Step 3 Leave a space of 6 to 8 inches behind the cabinet for the compressed air supply line There is a 2 inch hole provided on the bottom right side of the system back wall for air supply line access Page 6 Empire Abrasive Equipment Company 1 5 Electrical Connections IMPORTANT All electrical connections to the ProFormer cabinet should be made by a qualified electrician and must adhere to the codes standards and procedures specified by the authority having jurisdiction The customer is responsible for providing appropriate disconnecting means adjacent to the equipment for each incoming power circuit The standard power supply for the ProFormer 600 CFM 1 Y HP system is 220 240volts 60 cycle single phase Cabinets are also available pre wired for the optional power supplies listed in section 8 0 Options and Accessories The standard 220 240 volt single phase system is supplied with a 10 foot 4 wire line cord which is connected to the cabinet light box See Figure 3 Canadian CSA approved single phase cabinets have no line cord Electrical connections are made in the cabinet light box See Figures 3 All three phase systems have no line cord Electrical connections are made in the transformer contactor electrical box See Figure 1 If your system is a three phase power
52. t stream Pressure blast systems The fixed nozzle holder which bolts anywhere on the cabinet wall can be adjusted to position the nozzle in any orientation leaving 3 Fine Tuning Controls 4 Fine Tuning with Choke 5 Fixed Orifice Media Regulator 6 Low Media Level Sensor and Indicator Factory Installed Option 7 Harsh Media and Extended Wear Components 8 Fixed Gun or Nozzle Holder Page 39 Empire Abrasive Equipment Company Lo bth of the operator s hands free to manipulate work pieces 9 Fine Media Kits Vibrating screen A vibrating screen in the reclaimer plus an aerated media and for pressure regulator for pressure systems overcome flow problems associated systems only with very find abrasives 200 to 300 mesh range lightweight blast aerated media media plastics walnut shells etc and high humidity regulator 10 Magnetic Reclaim Magnetic reclaim separator reduces possible damage to delicate Separator substrates by removing steel and other ferrous contaminants from the blast media as it passes through the reclaimer The separator consists of an industrial magnet that can be removed through the reclaimer door for cleaning 11 Dust Collector Option Photohelic Automatically pulse the filters as required Controlled pulse NOTE For more jet cleaning information about options contact your Empire distributor or the factory Page 40 Empire Abrasive Equipment Company 9 0 ProFormer
53. the light box as shown in Figure 3 Page 8 Empire Abrasive Equipment Company IMPORTANT Before connecting power check that the voltage requirements of your ProFormer system are consistent with the voltage available at the installation site Figure 4 220 240 Volt Single Phase Figure 5 Three Phase Option Note The transformer is not included with dual source systems Page 9 Empire Abrasive Equipment Company 1 6 Compressed Air Connection IMPORTANT To operate properly your ProFormer system requires clean dry air Moisture or oil in the compressed air supply can contaminate the abrasive which can prevent it from flowing freely and cause inefficient blasting Though your system is equipped with a general purpose filter to remove small amounts of condensed water and oil from compressed air supply this filter is not designed to clean grossly contaminated air Step 1 Using the following two charts determine the proper air volume needed for your ProFormer system Step 2 The volume of air required for efficient operation of your system depends on the size of the nozzle you are using and the desired blast pressure The chart lists the minimum air requirements in SCFM for various nozzles and pressures AIR REQUIREMENTS SCFM FOR SUCTION BLAST 40 psi 60 psi 80 psi 100 psi Ya nozzle 1 8 air jet 12 17 21 26 5 16 nozzle 5 3
54. there is no air from the dust off The compressed air supply to the system is off compressed air is on by activating the dust off gun inside the blast cabinet gun turn the air supply to the system on If there is air from the dust off gun go to Step 2 Step 2 The blast pressure regulator is set to Zero Observe the blast pressure gauge If the gauge is at zero adjust the handle clockwise until the pressure is greater than 20 psi If there is no pressure replace the gauge and or regulator If the gauge shows that there is pressure and still no blast go to Step 3 Step 3 Failed interlock solenoid or foot treadle valve With the system on open a cabinet door and step on the foot treadle High pressure air should exit the door interlock air jet If there is no air go to Step 4 If there is air go to Step 5 Step 4 Failed foot treadle valve Turn the snap switch off and disconnect the air supply hose on the left side of the foot treadle Hold the loose hose end away from personnel and switch the system on High pressure air should exit the hose If no air exits the hose the interlock solenoid or snap switch is defective Replace the switch before replacing the valve If air exits the hose the foot treadle valve has failed Repair or replace the valve Step 5 The door air jets are leaking With both cabinet doors closed step on the foot treadl
55. uction or 1 501341 5 16 Di carb nozzle suction or X 501351 7 16 Di carb nozzle suction 501272 1 8 Di carb nozzle pressure or 1 501282 3 16 Di carb nozzle pressure or X 501292 Ya Di carb nozzle pressure 2 532701 Floodlights X X 20 524441 Door gasket X X 1 290182 Exhaust valve X 25 520792 Ya blast hose X 10 524802 5 8 blast hose X 10 520802 NW 5 nozzle washer for ceramic X nozzles 10 524101 QC washer X 1 518661 Foot treadle valve X X 2 pair 509891 Rubber gloves X X 1 524451 Window gasket X X 1 510401 Window safety glass X X 1 519001 Interlock solenoid X X 2 523523 Filter X X 1 523942 Sealing ring X 1 510431 Plunger for 1 cu ft pressure vessel X 522351 4 x 8 return hose or 1 X X 516103 6 x 3 Recovery hose 1 753551 MH 2 Gun Body X 505651 3 32 air jet or 505661 1 8 air jet or 2 X 505671 5 32 air jet or 505691 7 32 air jet 6 520822 Exhaust hose X 2 520252 Tubing fittings X 1 523592 Sure Flo metering tube 94 X Page 38 Empire Abrasive Equipment Company 8 0 Options and Accessories A variety of standard accessories are available for any ProFormer system If your production requirements change These accessories can be either factory you can add the options you need to installed or customer installed with a update your system minimum of cabinet modification 1 Optional Electricals 220 240 50 1 Voltage Frequency Phase of power available 208 60 3 220 240 60 3 380 5
56. ure to do so could result in serious injury Page 55 Empire Abrasive Equipment Company 10 0 Warranty Empire Abrasive Equipment Company Empire warrants all parts and equipment against defect in material and workmanship to the original purchaser for a period of three 3 years after shipment Upon prompt notification by the buyer to Empire components that are determined by Empire to be defective will be repaired or replaced at not additional charge LIMITATIONS 1 This warranty does not apply to normal wear items such as nozzles blast hose and reclaimers or to other components that are exposed to direct contact with blast media 2 The buyer must follow all recommended maintenance schedules see Operating Instruction on prior pages 3 Does not apply to misapplication of product 4 Unauthorized service repair improper installation improper operation improper maintenance alternations misuse neglect accident or excessive ambient conditions will void the warranty 5 If genuine Empire replacement parts are not used the warranty is void 6 Returned Material Authorization RMA form must be completed and accompany all returned goods Returns are not recognized without prior authorization and RMA number 7 Associated installation costs are excluded 8 Freight costs for goods returned to Empire are to be assumed by the buyer unless the parts are determined defective by Empire 9 Parts that are not sup
57. zle adapter steel 8 523881 O Ring 1 1 16 IDx 1 5 16 OD 9 520081 Nut hose clamp MH 2 O Page 49 Empire Abrasive Equipment Company 9 4 Dust Collector Components ux Description Number P 532523 Filter Assembly 2 516329 Diaphragm Valve 2 516328 Rebuild Kit Diaphragm Valve Hose 7 ID x 6 long Cover Gasket Neoprene 9 1 2 ID x 12 OD 6 515765 Waste Pail Page 50 Empire Abrasive Equipment Company 9 5 Blowers Fan amp Motor Blower Assemblies Standard CFM 2 5 140312 1 1 2 230 601 600 SEM 2 A Note Motor starters contactors interconnecting wiring and ducting not included Components 1 gt 549681 Motor 115 230V 60 Hz Single phase Motor part numbers shown in BOLD are supplied as standard most often 2 753661 Impeller fan blade 11 1 2 dia 5 8 ID s o 793511 Housing fan top 3 3 3 O poo 753521 Housing fan bottom 5 523251 Gasket fan housing 1 8 x 1 4 5 section 6 524361 Gasket mounting 3 required 7 73901 Guard fan outlet 8 554431 Clipfanguard 4requied S O 553182 Screw flat head 3 8 16 x 2 1 4 dust collector 551312 Screw flat head 3 8 16 x 1 1 4 slide gate A A S ZA a B 7515017 olt 1 4 20 x 1 751501 140759

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