Sponge-Jet Feed Unit User Manual
Contents
1. 3 Resume Blasting 6 13 Blast Pressure increases amp decreases continuously or Feed Unit exhausts intermittently while blasting 1 Check for holes in Twinline Fig H 4 and check for air leaks at all fitting connections Repair replace or tighten as necessary 2 Remove Exhaust Valve Cover Fig E 4 inspect for obstructions and check inner gasket for rips or any small holes Clean or replace as necessary 3 Resume Blasting Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 13 of 30 ooo 000 000 eee Troubleshooting continued 6 14 Panel testing in the non blasting mode This procedure will help to diagnose possible component problems on the Control Panel Fig B inset and in the Actuator system within the Pressure Vessel Fig A 4 This special diagnostic activity should only be performed under the direct guidance of a Sponge Jet Technical Service Representative 1 Turn the Blast Pressure Regulator Handle Fig B 5 counter clockwise to the off position by rotating the handle until the handle is removed from the body of the valve 2 Turn the Media Feed Pressure Regulator Handle Fig B 6 counter clockwise to the off position by rotating the handle until the handle is removed from the body of the valve 3 Remove Port Hole Cover Fig A 5 and evacuate enough abrasive media in the Pressure Vessel so that the Media Actuator Fig G 2 and the Actuator Tree Assembly Fig G 3 can be cl2. D hose above 91m 300 Use air lines larger than the recommended whenever possible C Fittings With 32mm 1 25 to 51mm 2 I D hose use 32 38mm 1 25 2 0 I D Universal 4 Lug Air Coupling With 51mm 2 and larger use Boss Fittings Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 16 of 30 EEN eee Sponge Jet Feed Unit Requirements Continued D Blast Hoses Sponge Media abrasive has been successfully blasted through 91m 300 of final Blast Hose However when choosing between long Air Supply Line and long Blast Hoses attempt to keep the Blast Hoses as short as practical Below are the recommended maximum lengths Upto 15m 50 of 32mm 1 25 I D Whipline connected to Upto 30m 100 of minimum 32mm 1 25 I D Blast Hose which may be further connected to Up to an additional 30m 100 of 38mm 1 5 Blast Hose Blast Hose lengths longer than 91m 300 are not recommended 7 2 Recommended Tools 6 Pliers Small Hammer 10 Channel Locks 12 Pipe Wrench Grease gun and grease Pneumatic tool oil 10 Adjustable Wrench WD 40 or equivalent Screw Drivers Regular and Phillips 10 T handle Hex Key 9 64 and 3 16 Wrenches 1 2 9 16 5 8 3 4 and 11 16 1 3 Recommended Spare Parts available from Sponge Jet 1 Exhaust Muffler 1 Air Motor 1 Auger Assembly 3 Nozzle Washers 1 Twinline Repair Kit 3 Hose Washers 1 Automatic Drain Kit 1 Timer 3 ft 5 32 pneuma
3. Jet Feed Unit User Manual 27 Sept 2007 Page 10 of 30 Th Troubleshooting continued 6 4 If air is felt flowing through Red Air Line 1 Stop flow of air from Red Air Line by placing thumb over opening This will test for a possible ruptured Exhaust Valve Diaphragm Fig E 2 If Feed Unit does not start up skip to Step 6 5 If Feed Unit does start up remove thumb from Red Air Line Replace the Exhaust Valve Diaphragm C we oc du Test Feed Unit for proper operation and resume blasting 6 5 If Feed Unit does not start up 1 Close Main Air Ball Valve Fig B 8 and allow Feed Unit to depressurize 2 Replace On Off Control Valve Fig C 1 3 Test Feed Unit for proper operation and resume blasting 6 6 Feed Unit will not stop running 1 Depress the Emergency Stop Button Fig B 1 on the Control Panel Fig B inset Feed Unit should stop 2 If Feed Unit will not stop close Main Air Ball Valve Fig B 8 and allow the Feed Unit to depressurize fully Open Main Air Ball Valve 3 Ifa continuous leak of air is heard from the Deadman Handle Fig H 6 then reverse the Twinline Quick Connect Fittings Fig A 6 at the Feed Unit end of the Twinline re test according to Section 4 0 and resume blasting 4 If Feed Unit pressurizes without depressing the Deadman Handle contact Sponge Jet immediately at 800 776 6435 USA or 603 431 6435 6 7 Deadman Control is exhausting air while in shutdown condition 1 Reverse Twinli
4. Out Trap The clean out trap catches foreign debris not meant to pass through the nozzle The clean out trap must be periodically emptied of all debris 4 Auger Manual Rotation Handle Handle used to turn Auger to check for Auger jams lo seats ie 5 Auger Drive Chain MME The Auger Drive Chain in conjunction with the Auger Sprocket rotates the Auger Shaft 6 Auger Sprocket The Auger Sprocket drives the Auger 7 Air Motor Sprocket The Air Motor Sprocket drives the Auger Drive Chain 8 Auger The Auger feeds Sponge Media abrasives into the air stream Figure J Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 29 of 30 NOTES MODEL SERIAL Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 30 of 30
5. media abrasive They are removed from the working mix through the classifying process and flow through the bottom port of the Classifier Fines can be reused in some circumstances by adding a portion of the fines generated back into the working mix described above The exact amount of fines reintroduced will be determined by how much dust can be tolerated in the work area Many users find other uses for fines For example a contractor used silver media on the superstructure of a paper machine to remove paint corrosion and contaminates As the Silver Sponge Media abrasive broke down the contractor saved the fines in 250L 55 gallon drums Once a year at this particular paper mill each boiler is shut down for cleaning Dust levels are not a significant problem inside the boiler therefore Silver Sponge Media abrasive fines were utilized as a cleaning abrasive within the boiler WARNING Fines should not be reused when working with hazardous substances such as lead paint Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 18 of 30 ooo 00 0 000 ee Sponge Jet Feed Unit Requirements Continued 7 5 Media Uses and Approximate Settings The settings and descriptions below are approximate Individual applications and uses will vary BP Blast Pressure MFP Media Feed Pressure Green Sponge Media General contaminant cleaning Soot removal from stone and concrete Cleaning painted surface while provi
6. 0 776 6435 or 603 431 6435 6 1 Feed Unit will not run 1 Confirm the Main Air Ball Valve Fig B 8 is open 2 Confirm the Emergency Stop Button Fig B 1 is not pushed in 3 Confirm the Twinline Fig H 4 connections at the Feed Unit and at the Deadman Handle Fig H 6 handle are secure 4 Check for holes or other damage in the full length of the Twinline and repair as necessary 5 Check that the Line Pressure Gauge Fig B 4 registers adequate pressure If necessary turn on or charge the compressor 6 Test Feed Unit for proper operation if this did not solve the problem proceed to Step 6 2 otherwise resume blasting 6 2 Check Deadman Trigger Handle 1 Depress and then release the Deadman Handle Fig H 6 with the Main Air Ball Valve Fig B 8 open and the Feed Unit pressurized 2 Listen for an exhaust of air from behind the Deadman Handle when handle is released 3 Ifan exhaust of air is heard but the Feed Unit will not run skip to Step 6 3 4 Ifan exhaust is not heard confirm you are using a Sponge Jet approved Deadman Handle and call Sponge Jet Inc Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 6 3 If an exhaust of air is heard when the Deadman Control is released 1 Remove the Red Air Line from the Exhaust Valve Fig E 3 2 While holding the Red Air Line securely depress the Deadman Handle Fig H 6 and feel for a blast of air at the Red Air Line Sponge
7. 4 Twinline The Twinline flows the pneumatic circuit of air from the Deadman to the Aquamatic Valve 5 Clean Out Screw depending on model The Clean Out Screw provides maintenance access to the internal components of the Deadman Handle 6 Deadman Handle The Deadman Handle allows for on or off operation of the Deadman System Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 27 of 30 Figure I Control Panel Back View 1 T Handle Regulator The T Handle Regulator Controls the blast pressure and media feed pressure 2 Desiccant Filter The Filter removes vapor level moisture from the pneumatic Timer Circuit 3 Timer The Timer is a pneumatic timing mechanism that regulates the delay interval of the Actuator s motion 4 Control Valve Air Motor The Control Valve Air Motor provides the pneumatic signal that activates the Air Motor 5 Control Valve Actuator The Control Valve Actuator provides the pneumatic signal that activates the Actuator Tree Assembly 6 Emergency Stop Valve The Emergency Stop Valve provides the pneumatic signal that stops the Feed Unit instantly Figure H Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 28 of 30 Figure J Lower End Left Side View 1 Air Motor The Air Motor through adjustment at the control panel regulates the air media mixture by turning the Auger 2 Auger Chain Guard The Auger Chain Guard prevents injury from contact with the drive chain 3 Clean
8. Sponge Jet Sponge Blasting System Sponge Jet Feed Unit User Manual SPONGE Sponge Jet Inc USA 235 Heritage Ave Ste 2 Portsmouth NH 03801 tel 603 431 6435 www spongejet com Sponge Jet Feed Unit User Manual 27 Sept 2007 Model 400HP Sponge Jet Europe Ltd Robson Way Blackpool United Kingdon FY3 7PP tel 44 0 1253 390731 Page 1 of 30 ooo 000 0 00 eee 1 0 Introduction Sponge Jet Feed Unit equipment is the propulsion unit for blasting Sponge Jet Sponge Media abrasive Its purpose is to deliver any of a wide variety of Sponge Media abrasives during surface preparation cleaning and or decontamination The equipment is designed for operation with clean dry compressed air by a skilled and trained operator in temperatures above freezing Maximum inbound pressure should be limited to 8 6 bar 125 psi with a recommended maximum output of 6 bar 85 psi at the nozzle regulated on the Feed Unit Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 2 of 30 T o ke 1 1 Warning 1 The use of bleeder type Handle handles may cause unintentional start up without warning which can result in personal injury 2 To prevent electrostatic buildup and possible electric discharge the unit and work piece must be properly bonded and grounded 3 Connecting unit to a compressed air source exceeding the recommended pressure is not only dangerous but may also damage the pressure regul
9. Valve verify that a minimum of 7 bar 100 psi of inbound supply air registers on the Line Pressure Gauge Fig B 4 on the Feed Unit s Control Panel Fig B inset Page 6 of 30 ik Operation amp Shutdown After the operator depresses the Deadman Handle Fig H 6 allow the Feed continued Unit to pressurize This may take 5 to 10 seconds CAUTION Do not cycle the Deadman Handle while waiting for abrasive at the Nozzle as in conventional abrasive blasting Cycling the Deadman Handle will usually clog the Blast Nozzle and Blast Hose Once the Line Pressure Gauge Fig B 4 Blast Pressure Gauge Fig B 2 and the Media Feed Pressure Gauge Fig B 3 have stabilized in operation adjust the Blast Pressure Regulator Handle Fig B 5 and the Media Feed Pressure Regulator Handle Fig B 6 to the desired levels Clockwise adjustments increase pressures Do not exceed a Blast Pressure Gauge reading of 6 2 bar 90 psi Adjust the Media Feed Pressure Gauge to the desired level usually 2 8 bar 40 psi for initial operation using the Media Feed Pressure Regulator Handle Confirm that the Blast Pressure Gauge remains at the desired level Once the desired Blast Pressure Gauge and Media Feed Pressure Gauge levels are obtained visually confirm that the Auger Fig J 8 is rotating and that the Agitation Indicator Eye Fig B 7 is functioning These levels should remain constant unless adjusted Sponge Blast the desir
10. ations in the Sponge Jet Sponge Blasting System 4 No warranty is given or implied as to the use of equipment and media for any particular application Always check suitability of the system on small test areas prior to use 5 Moisture Separator Automatic Drain Offs must remain free of contaminants to drain properly 6 When operating the Feed Unit in conditions of high ambient air temperature or humidity the Feed unit must be equipped with auxiliary moisture separation and temperature reduction devices supplied by the end user Unless otherwise noted this manual covers equipment maintenance and operation for Sponge Jet 400 HP and 400 HPJ Feed Unit models Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 3 of 30 ooo 00 00 eee 2 0 Transportation The Sponge Jet Feed Unit is designed to be transported in three different manners Manual Wheeling Forklift and the Overhead lift Manual Wheeling The Sponge Jet Feed Unit is equipped with four caster wheels Two casters swivel for steering one of which locks for stationary operation WARNING Manual transport is only intended for use on level smooth surfaces Transport or operation in areas of uneven grade or unstable flooring will require additional restraining precautions Forklift The Sponge Jet Feed Unit is designed for forklift transport using the provided double pockets on two sides of the frame WARNING Forklift transport not utilizin
11. aust Valve allows air contained in the pressure vessel to escape during depressurization 4 Exhaust Valve Cover The Exhaust Valve Cover secures the Exhaust Valve Diaphragm during operation of the Feed Unit Figure E Figure F Relief Valve Optional 1 Relief Valve The Relief Valve automatically releases air pressure from the pressure vessel when the internal air pressure exceeds 8 6 bar 125 psi Figure F Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 25 of 30 Figure G Internal View 1 Pop Up Valve The Pop Up Valve seals the pressure vessel during blasting 2 Media Actuator The Media Actuator is a pneumatic motor that turns the actuator tree assembly inside the pressure vessel The media actuator assists in providing a continuous sponge media supply during blasting 3 Actuator Tree Assembly The Actuator Tree Assembly agitates sponge media in the pressure vessel 4 Actuator Chain The Actuator Chain assists in movement of media through the pressure vessel Figure G Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 26 of 30 Figure H Deadman Trigger Assembly 1 Blast Hose Figure H The Blast Hose conveys the media from the Pressure Vessel to the Nozzle 2 Nozzle Connector The Nozzle Connector connects the Nozzle to the Blast Hose 3 Blast Nozzle The Blast Nozzle is an acceleration tip designed to focus the blasting media at a desired location for blasting activities
12. cal Service at 800 776 6435 USA or 603 431 6435 for further assistance Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 15 of 30 ooo 00 0 00 eee 1 0 Sponge Jet Feed Unit Requirements Equipment and Air requirements I D Inner Diameter 0 D Outer Diameter 7 1 Feed Unit A Compressor 10 6 m min 375 CFM minimum at 7 6 bar 110 psi for a 8 nozzle 16mm 1 2 Occasionally a compressor is equipped with undersized outlets To allow access to full compressor potential compressor air outlet s should be no smaller than the recommended Supply Line diameters below Nozzle size determines the volume of air required to drive the media to the surface at a given pressure The chart below depicts the volume of air required to support three different nozzle sizes at 6 0 bar 90 psi The minimum compressor size recommendations below include a 50 reserve factor which is intended to account for the loss associated with friction and some nozzle wear Abrasive Minimum Compressor Req Nozzle Size Lb per Min Hr m CFM with Reserve 7 11mm 7 16 36 8 408 6 4m 225 10 6m 375 CFM 8 13mm 1 2 8 480 7m 250 10 6 12m 375 425 CFM Remember the smallest l D in the entire system determines the maximum airflow volume for the entire blast system B Air Supply Hose requirements 1 32mm 1 25 I D hose up to 61m 200 2 51mm 2 ID hose up to 91m 300 3 72mm 3 I
13. ding slight profile for repainting Settings BP 2 1 5 9 bar 30 85 psi MFP 1 7 3 1 bar 25 45 psi Profile Generated Slight Etch White Sponge Media Paint removal from composites Paint removal on delicate metallic substrates Tenacious contaminate removal Mold cleaning of baked on residues Settings BP 2 1 4 1 bar 30 60 psi MFP 1 7 3 1 bar 25 45 psi Profile Generated Not applicable de glossing occurs Brown Sponge Media Light paint and contaminant removal Clean and profile existing paint for recoating Paint de glossing Settings BP 2 1 5 9 bar 30 85 psi MFP 1 4 3 1 bar 20 to 45 psi Profile Generated 25 50 microns 1 2 mils Silver Sponge Media Paint and contaminant removal on steel Paint and contaminant removal on aluminum Paint and contaminant removal on concrete masonry and block General surface preparation activities Rust and mill scale removal Char removal Settings BP 2 8 5 9 bar 40 85 psi MFP 1 4 3 1 bar 20 45 psi Profile Generated 63 113 microns 2 5 4 5 mils Red Sponge Media Same as silver but generally used on thicker coatings Elastomeric coatings Settings BP 2 1 5 9 bar 30 85 psi MFP 1 4 3 1 bar 20 45 psi Profile Generated 100 150 microns 4 6 mils Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 19 of 30 ooo 000 0 00 eee Sponge Jet Feed Unit R Requirements Continued 7 6 Containment Containm
14. e Port Hole Cover allows access to the inside of the pressure vessel 6 Twinline Quick Connect Fittings The Twinline Quick Connect fittings attach the twinline from the Deadman Handle to the Feed Unit T Crab Assemhly The Crab Assembly secures the Port Hole Cover sealing the Pressure Vessel for operation during blasting The Crab assembly includes one or more Crab Braces and the same amount of nut and bolt assemblies Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 21 of 30 Figure A Control Panel il Figure C Sponge Jet Feed Unit User Manual 27 Sept 2007 Figure B 1 Emergency Stop Button The Emergency Stop Button stops the Feed Unit instantly when depressed 2 Blast Pressure Gauge The Blast Pressure Gauge indicates the amount of pressure exiting the Feed Unit The recommended pressure for effective coatings removal and optimal media reuses is 6 2 bar 90 psi or less 3 Media Feed Pressure Gauge The Media Feed Pressure Gauge indicates the amount of air pressure being supplied to the Air Motor This in turn relates to how much Sponge Media that is introduced into the air stream The recommended pressure for optimal coatings removal is 1 4 2 8 bar 20 40 psi 4 Line Pressure Gauge The Line Pressure Gauge indicates the amount of pressure entering the Feed Unit from the compressor The recommended inbound pressure is 8 bar 120 psi 5 Blast Pressure Regulator Handle The Blast Pres
15. early seen By following the above procedure when testing the panel and actuator system the auger will not be rotating and the Feed Unit will not be blasting This will allow the operator to diagnose each component individually Normal actuator motion is 90 degrees alternating direction every 1 2 seconds The components should not rotate beyond 90 degrees 6 15 Air flows through Blast Nozzle but with no media in the air stream and the Auger is rotating 1 Adjust the panel to the Non Blasting Mode 6 14 2 Remove top orange output airline on the Desiccant Filter Fig 2 depress the Deadman Handle Fig H 6 and check for airflow from top of Desiccant Filter which should be continuous 6 16 If no airflow is felt from the top of the Desiccant Filter 1 Replace the Desiccant Filter Fig I 2 noting the position of the airlines when replacing the filter It is necessary to switch airline fittings from old filter to new 2 Re test for airflow and check for proper motion of the Agitation Indicator Eye Fig B 7 When operating properly a light pulse of air can be felt exiting from the top of the Timer Fig I 3 3 Resume blasting Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 14 of 30 Th Troubleshooting continued 6 17 If no pulse of air is felt at the top of the Timer 1 Check that the Timer Fig 3 is set properly at 2 75 for the 400L Reset if necessary 2 Test for pulse of air and check for prop
16. ed surface 4 2 Shutdown of the Feed Unit The red Emergency Stop Button Fig B 1 is located on the Control Panel Fig B inset can be used to stop all functions Normal shutdown during operation is by release of the Deadman Handle Fig H 6 Close the Main Air Ball Valve Fig B 8 Shut down the compressor Close the supply line ball valve at the compressor and the Main Air Ball Valve at the Feed Unit Compressor supplied by others Once the supply of air from the compressor to the Feed Unit has been closed open the Main Air Ball Valve at the Feed Unit Point the Blast Nozzle Fig H 3 at the working substrate away from people and depress the Deadman Handle Fig H 6 Keep the Deadman Handle depressed until all remaining air is vented from the Feed Unit and the Blast Hose Fig H 1 Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 7 of 30 ooo 00 0 00 eee Operation amp Shutdown Once all gauges on the Feed Unit Control Panel Fig B inset read 0 PSI continued confirm that the supply line from the compressor is soft amp pliable If the prior steps have been followed exactly the supply line from the compressor to the Feed Unit should now be vented and safe to disconnect WARNING Before disconnecting the compressor supply line ensure that all gauges on both the Feed Unit and the Compressor register 0 PSI Allowing for adequate evacuation time as well as determining hose pliabili
17. ensitive control panel instrumentation Page 23 of 30 Figure D Lower End 1 Choke Valve The Choke Valve is normally fully open The Choke Valve when closed directs the air stream through the Pressure Vessel and can be used to clean out the Feed Unit The choke valve in the closed position causes sponge media to quickly exit the Feed Unit 2 Air Motor Moisture Separator The Air Motor Moisture Separator which automatically drains when full protects the air motor from excess moisture 3 Air Motor Lubricator The Air Motor Lubricator injects oil automatically from a reservoir into the air stream 4 Auger Tunnel End Cap The Auger Tunnel End Cap allows access to the auger for cleaning purposes 5 Blast Hose Connection The Blast Hose Connection is a two pronged universal Blast Hose connector fitting which allows for connection from the Blast Hose to the Feed Unit 6 Clean Out Trap The Clean Out Trap is removable to check for obstructions at the Auger Figure D Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 24 of 30 Figure E Exhaust System 1 Exhaust Muffler The Exhaust Muffler reduces the noise caused by the air exiting the Feed Unit The Exhaust Muffler must be periodically emptied of Sponge Media and or other foreign debris 2 Exhaust Valve Diaphragm The Exhaust Valve Diaphragm regulates the release of air pressure from the Feed Unit when the Deadman Handle is released 3 Exhaust Valve The Exh
18. ent is an integral part of the Sponge Jet process as with any abrasive blasting Sponge Jet Sponge Media is recyclable reusable and environmentally friendly due to the low volumes of waste and dust generated To take advantage of these properties containment must be used to capture and reclaim the sponge Under normal conditions when abrasive Sponge Media is being used lightweight 6 to 10 mil poly containment can contain the abrasive sponge More stringent containment may be required when working with hazardous substances and in areas where dust is a critical concern These types of containment may also require negative air machines to further reduce dust levels inside the containment as well as outside the containment When working with hazardous substances always follow local state and federal guidelines concerning proper containment containment ventilation and monitoring procedures Containment also serves another purpose it keeps the working area clean from foreign debris Once the containment has been erected a thorough cleaning of the contained area should be the next step This will serve to minimize any foreign debris that if reused with the sponge media could clog or jam the equipment By initially cleaning the area many unnecessary problems and machinery inconveniences can be avoided 7 7 Safety Operation of the Sponge Jet system necessitates the use of certain safety equipment Because the Sponge Blasting System is an indu
19. er motion of the Agitation Indicator Eye Fig B 7 and Actuator Tree Assembly Fig G 3 3 Resume blasting 6 18 If air is still not felt at the top of the Timer 1 Remove the 2 screws on face of the Timer Fig I 3 and replace the Timer making sure to note the position of the hoses on the back of the Timer 2 Test the new Timer for pulse of air and check for proper motion of the Agitation Indictor Eye Fig B 7 and the Actuator Tree Fig G 3 Resume blasting 6 19 If a pulse of air is felt at the top of the Timer but media flow is still not present or consistent 1 With the Deadman Handle Fig H 6 depressed observe that the Agitation Indicator Eye Fig B 7 is blinking and appears to be working 2 If not call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 3 If it does appear to be blinking reduce the blast pressure to 0 bar O psi on the Blast Pressure Gauge Fig B 2 using the Blast Pressure Regulator Handle Fig B 5 4 Reduce the Media Feed Pressure to 0 psi by turning the Media Feed Pressure Regulator Handle Fig B 6 counter clockwise 5 Open the Port Hole Fig A 5 cover to the blast pot 6 Depress the Deadman Handle Fig H 6 and observe the activity of the Actuator Tree Assembly Fig G 3 It should rotate 90 degrees in both directions with motion occurring about every two seconds 7 If it still does not operate call Sponge Jet Techni
20. f air without media is achieved slowly return the Media Feed Pressure Gauge Fig B 3 back up to the desired pressure by adjusting the Media Feed Pressure Regulator Handle in a clockwise direction 6 11 Air Flows through nozzle but with no media and auger is rotating Note After start up media flow is not instantaneous Even with only 50 of final Blast Hose initial media flow may require 15 seconds Stabilized media flow may require up to 4 minutes Conditions may change that period up or down 1 Checkthat Feed Unit contains an adequate amount of media Fill as necessary 2 While the Feed Unit is in operation check that the Agitation Indicator Eye Fig B 7 is blinking from green to black every few seconds while machine is pressurized and operating If the Agitation Indicator Eye is not changing call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 3 After depressurizing the system in accordance with Section 4 2 open the Port Hole Cover Fig A 5 and check that Actuator Tree Assembly Fig G 3 is attached to Media Actuator Fig G 2 Reconnect if necessary 6 12 Too much media exits the Nozzle and or media is pulsing out of nozzle 1 Check that the Choke Valve Fig D 1 is in full open position e g parallel to pipe Open if necessary and continue 2 Check the Media Feed Pressure Gauge Fig B 3 is not set above 3 4 Bar 50 psi if so reduce the pressure as necessary
21. g the fork pockets will result in unstable operation and unpredictable load shifts and possible damage and or injury Overhead Lifting The Sponge Jet Feed Unit is equipped with two lifting lugs at the top of the pressure vessel intended for use with a proper lift set WARNING Transportation to and from job sites must involve adequate restraint or packing for the entire duration of the trip Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 4 of 30 ooo 00 00 ee Note 1 8 6 bar 125 psi sustained maximum 3 Safety inbound pressure The Sponge Jet Inc Feed Unit is a pressurized positive air feed system Only certified operators should adjust maintain and repair this equipment Sponge Jet offers a certification program to train operators in the mechanics of the equipment as well as in Sponge Blasting applications 1 Use only Sponge Jet approved positive feed Deadman Handle Fig H 6 2 Before performing any maintenance on the Feed Unit make sure equipment is off and depressurized The Main Air Ball Valve Fig B 8 and the Emergency Stop Button Fig B 1 on the Control Panel Fig B inset should both be in the off position to insure the Feed Unit is not accidentally pressurized 3 From the compressor under normal circumstances the inbound pressure should never exceed 8 6 bar 125 psi The pressure can be checked at the compressor or by the Blast Pressure Gauge Fig B 2 on the Feed Un
22. he Exhaust Muffler Fig E 1 Remove any accumulated media from within it and reinstall WARNING Do not operate equipment without muffler in place 5 2 The following maintenance should be performed after each 80 hours of operation e Remove and inspect the interior of the Secondary Water Separator Fig B 10 Remove any contaminants that have accumulated in the bowl Reinstall e Visually inspect the O ring on the Secondary Water Separator and Air Motor Moisture Separator Fig D 2 Replace if the O ring has been damaged or worn 5 3 The following maintenance should be performed monthly e Remove Auger Chain Guard Fig J 2 inspect the condition of the Auger Drive Chain Fig J 5 Apply lightweight lubricating oil as necessary then replace the Auger Chain Guard e Lubricate each Stationary and Swivel Caster Wheel with multi purpose grease as needed e Inspect all pneumatic component supply lines for wear damage and connection security Page 9 of 30 ooo 00 0 00 eee 6 0 Troubleshooting Inevitably circumstances arise that can adversely effect the performance of the equipment The following section will guide a trained operator in the proper diagnosis of equipment operating problems It is strongly recommended these procedures be retained with each Feed Unit as a reference guide Sponge Jet Inc Technicians are available 24 hours a day 365 days a year by calling the U S A 800 SPONGEJET 80
23. it Control Panel 4 When operating the Feed Unit people in proximity should always wear eye and hearing protection with the appropriate respiratory equipment which may depend on the type of coating or contaminate being removed 5 Prior to pressurizing the Feed Unit safety pins or restraints should be fitted at all Bull Hose and Blast Hose couplings to prevent accidental disconnection 6 Before blasting all pneumatic lines should be visually inspected for holes wear and proper fit 7 The Port Hole Cover Fig A 5 must be in place and secure prior to and during operation 8 Never reach into the pressure pot area of the Feed Unit through the Hopper Fig A 2 9 Never point the Blast Nozzle Fig H 3 towards yourself or others 10 Do not remove the Auger Chain Guard Fig J 2 to the Auger while the Feed Unit is in operation 11 If the optional Relief Valve Fig F 1 is activated contact Sponge Jet immediately at 800 776 6435 USA or 603 431 6435 Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 5 of 30 Sponge Jet Feed Unit User Manual 27 Sept 2007 4 0 Operation amp Shutdown 4 1 Operation of the Feed Unit Working temperature conditions for the Feed Unit should always be above freezing Verify that the machine is secured in an appropriate manner for operation Inspect the Blast Nozzle Fig H 3 for wear and proper engagement of hose connections Once the Blast Nozzle bore has worn 2mm 1 16 be
24. ne Quick Connect Fittings at Feed Unit end of Twinline 2 Ifthe Deadman Handle Fig H 6 is still leaking remove Clean Out Screw Fig H 5 depending on model in Deadman Handle Check for debris within the Deadman Handle clean and replace Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 11 of 30 ooo 000 0 eee Troubleshooting continued 6 8 Auger will not begin rotating 1 First check that the Media Feed Pressure Gauge Fig B 3 registers adequate operating pressure 1 4 bar 10 to 60 psi while the Feed Unit is engaged 2 f necessary increase this pressure by turning the Media Feed Pressure Regulator Handle Fig B 6 in a clockwise direction The pressure level of the Media Feed Pressure Gauge should increase If Air Motor Fig J 1 sticks at startup or becomes sluggish at lower pressures it may be necessary to add pneumatic hand tool oil to the Air Motor Lubricator Fig D 3 The Air Motor chronically starts with difficulty becomes sluggish or seizes completely it may need to be rebuilt Sponge Jet Inc offers a rebuild service Call Sponge Jet Inc at 800 776 6435 USA or 603 431 6435 for details 6 9 Auger stops rotating during normal operation 1 Stop blasting depressurize the Feed Unit close the Main Air Ball Valve Fig B 8 and depress the Emergency Stop Button Fig B 1 2 Rotate Auger Manual Rotation Handle Fig J 4 by hand only 1 3 rotations clockwise 3 Ifthe Auge
25. r Manual Rotation Handle will not turn by hand remove the Clean Out Trap Fig D 46 and rotate the auger back and forth until the obstruction falls out 4 Replace the Clean Out Trap Rotate Auger Manual Rotation Handle to make sure that the Auger Fig J 8 is free of obstruction 5 Resume blasting Return the media feed pressure to its desired level between 2 8 bar 40 psi If the auger still does not rotate call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 6 10 Air Flow Through Nozzle Suddenly Stops 1 Stop any attempt to restart and depress the Emergency Stop Button Fig B 1 immediately Depressurize the Feed Unit and close the Main Air Ball Valve Fig B 8 2 Remove Blast Nozzle Fig H 3 from Blast Hose Fig H 1 and inspect for obstruction Remove obstructions as necessary 3 Disconnect all Blast Hose connections and inspect for obstructions Remove obstructions as necessary 4 Remove the Auger Tunnel End Cap Fig D 4 Check for media clog s Remove clogs if necessary Replace Auger Tunnel End Cap Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 12 of 30 ooo 00 0 0 eee Troubleshooting continued If an obstruction occurs in the Auger Tunnel End Cap area of Feed Unit rotate the Media Feed Pressure Regulator Handle Fig B 6 in a counter clockwise direction to the off position Clear the obstruction 6 Resume blasting Once a full stream o
26. strial abrasive blasting technology commercial use of the product in the USA falls under the scope and power of OSHA and other local regulatory agencies Be aware of the rules governing usage in your own circumstances Certain types of safety equipment are almost universally required Proper safety equipment includes but is not limited to Hearing protection Eye protection safety glasses safety shield blasting hood or helmet Respiratory protection as required Gloves Safety shoes Protective clothing To ensure proper compliance always follow local state and federal guidelines When using Sponge Jet to remove hazardous materials other safety issues will arise such as quality of air in containment quality of air outside containment and worker exposure limits Refer to local state and federal guidelines as situations require Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 20 of 30 ooo 00 0 0 00 eee Figures Sponge Jet 400HP Feed Unit Figures Figure A 1 Hopper Lid Optional The Hopper Lid prevents any foreign debris from entering the Feed Unit should be placed on the hopper during Feed Unit operation 2 Hopper The Hopper holds the reserve Sponge Media for the Feed Unit 3 Lifting Lug The Lifting Lugs are used to properly attach lifting slings to the Feed Unit 4 Pressure Vessel The Pressure Vessel is where sponge media is stored during blasting 5 Port Hole Cover Th
27. sure Regulator Handle allows for the adjustment of airflow to the Blast Nozzle 6 Media Feed Pressure Regulator Handle The Media Feed Pressure Regulator Handle allows the pot tender to regulate the amount of media provided to the airline for blasting 7 Agitation Indicator Eye The Agitation Indicator Eye shows the rate at which the Sponge Jet Actuator Tree Assembly is actuating within the pressure vessel 8 Main Air Ball Valve The Main Air Ball Valve starts and stops the airflow from entering the Feed Unit This device is not a regulation device 9 Supply Line Connection The Supply Line Connection uses a four prong Chicago fitting on a 51mm 2in National Pipe Thread NPT nipple 10 Secondary Water Separator The Secondary Water Separator separates water from the air stream with an 80 micron filter Page 22 of 30 Figure C Sponge Jet Feed Unit User Manual 27 Sept 2007 Figure C 1 On Off Control Valve The On Off Control Valve serves as the Feed Unit s on off switch When the On Off Control Valve is open blasting is initiated When the On Off Control Valve is closed the Feed Unit is depressurized and turns off 2 Blast Pressure Regulator The Blast Pressure Regulator regulates the amount of airflow traveling through the Feed Unit and out to the nozzle 3 Control Panel Moisture Separator The Control Panel Moisture Separator is intended to remove any remaining water or other liquid contaminants from the s
28. tic hose 3 ft 3 8 pneumatic hose 1 Control Valve 1 Desiccant Filter 1 Deadman Handle 2 Exhaust Valve Diaphragm 1 0 ring for Secondary Water Separator Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 17 of 30 ooo 00 0 00 eee Sponge Jet Feed Unit Requirements Continued 7 4 Media Management Media Management is the way new and used sponge are added together while work is in process for best results and economy As sponge is blasted and recycled the sponge breaks down into smaller and more abrasive particles By adding and mixing new sponge with the used sponge the result will be that the larger particles of sponge will suppress the dust generated by the fast cutting used sponge This mixture of new and used sponge is called the working mix All blasting applications will require specific consumption analysis As a rule of thumb Using a 1 2 8 Nozzle 1 2 bag of new Sponge Media abrasive should be added to the working mix every 30 minutes of nozzle blast time New Sponge Media abrasive can be mixed with used Sponge Media abrasive in one of two ways 1 By hand in a bucket or in media bags after the used Sponge Media abrasive has been classified 2 By mixing the new Sponge Media abrasive with used Sponge Media abrasive prior to classifying at the top of the classifier This will allow the classifier to perform the mixing Fines Fines are small particles of contaminant and spent
29. ty are important safety precautions that must be utilized when disconnecting any high pressure air supply line e Ifthe Feed Unit is to remain out of service for more than one day remove by vacuum all residual media through from inside the Pressure Vessel Fig A 4 of the Feed Unit and the Hopper Fig A 2 e The resulting product of process must be disposed of in accordance with local and or Federal regulations governing waste disposal Sponge Jet Feed Unit User Manual 27 Sept 2007 Page 8 of 30 Sponge Jet Feed Unit User Manual 27 Sept 2007 5 0 Maintenance To provide long and reliable service the components of the Sponge Jet Feed Unit require routine maintenance During all maintenance operations the Feed Unit must be shut down 5 1 The following maintenance activities should be performed prior to each use of the Feed Unit e Inspect the Blast Nozzle Fig H 3 for wear Once the nozzle bore has worn 2mm 1 16 beyond its original intended diameter it should be replaced e Remove the Blast Nozzle and ensure that it is equipped with a nozzle washer between the nozzle and its holder Reinstall the nozzle and washer taking care to see that the washer lies flat in its seat e Visually inspect all Blast Hose Fig H 1 and connections Repair or replace any worn or damaged components Ensure that all couplings are equipped with coupling gaskets and safety pins and that they are properly installed e Inspect and clean t
30. yond its original inside diameter it should be replaced Remove the Blast Nozzle and ensure that it is equipped with a Nozzle Washer Replace the Blast Nozzle and Nozzle Washer insuring that the Nozzle Washer lies flat in its seat Visually inspect all Blast Hose Fig H 1 and connections Repair or replace any worn or damaged components Ensure that all couplings are equipped with coupling gaskets and safety pins or hose restraints and that they are all properly installed Connect the compressor to Feed Unit Supply Line Connection Fig B 9 and secure with safety pins or restraints Sponge Jet supplies Feed Units with a single four 4 lug Chicago fitting on a 2 National Pipe Thread NPT nipple WARNING System is designed for a maximum 8 6 bar 125 psi Failure to install safety pins and proper restraints dog leash whip checks on the bull hose may result in personal injury Securely attach the Sponge Jet Feed Unit s Port Hole Cover Fig A 5 with the gasket in place Connect the Blast Hose Fig H 1 and the Twinline Fig H 4 Sponge Jet supplies blast hose connections with two 2 lug Universal fittings Fill the Feed Unit through the Hopper Fig A 2 with the desired amount and type of Sponge Media abrasive Please see Section 7 4 for media management Check that the Main Air Ball Valve Fig B 8 is in the closed position and charge the supply line At the nozzle operator s command open the Main Air Ball
Download Pdf Manuals
Related Search