Sponge-Jet Feed Unit User Manual
Contents
1. Test new timer for pulse of air and check for proper motion of the Agitation Indictor Eye Figure A 9 and the Actuator Tree Assembly Fig D 29 Resume blasting 6 9 10 If a pulse of air is felt at the top of the timer 1 assembly but media flow is still not either present or consistent With the Deadman Trigger Handle Fig E 36 depressed observe that the Agitation Indicator Eye Fig A 9 is blinking and appears to be working If itis not contact Sponge Jet Inc in the U S A 800 776 6435 or 207 439 0211 for more detailed technical assistance If it does appear to be blinking reduce the blast pressure to 0 bar O psi on the Blast Pressure Gauge Figure A 7 using the Blast Pressure Regulator Adjustment Handle Figure A 16 Page 16 of 31 ooo 000 0 0 eee Troubleshooting continued 4 Reduce the Media Feed Pressure to 0 psi by turning the Media Feed Adjustment Handle Fig A 15 counter clockwise 5 Open the Port Hole Figure B 19 cover to the blast pot 6 Depress the Deadman Trigger Figure E 36 and observe the activity of the Actuator Tree Assembly Figure D 29 It should rotate 45 degrees in both directions with motion occurring about every two seconds 7 If it still does not operate call Sponge Jet Inc US Technical Support at 1 800 776 6435 207 439 0211 or fax 207 439 0309 for further assistance Sponge Jet Feed Unit User Manual 05 Oct 06 Page 17 of2. Sponge Blast the desired surface 4 2 Shutdown of the Feed Unit The red Emergency Stop Button Fig A 17 located on the control panel can be used to stop all functions Normal shutdown during operation is by release of the Deadman Trigger Fig E 36 Close the Main Air Ball Valve Fig A 14 Shut down the compressor Close the supply line ball valve at the compressor 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 Fig A 14 at the Feed Unit Point the Blast Nozzle Fig E 38 at the working substrate and depress the Deadman Trigger Fig E 36 Keep the Deadman Trigger Fig E 36 depressed until all remaining air is vented from the Feed Unit and the Blast Line Sponge Jet Feed Unit User Manual 05 Oct 06 Page 7 of 31 ooo 00 0 000 eee Operation amp Shutdown Once all gauges on the Feed Unit Control Box read 0 PSI confirm that continued the supply line from the compressor is soft amp pliable If so it is safe to disconnect the line from the Feed Unit 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 pli
3. 8 Nozzle 1 2 bag of new Sponge Media abrasive should be added to the working mix every 30 minutes of nozzle blast time Using a 3 8 6 nozzle 1 4 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 media abrasive They are removed from the working mix through the classifying process and flow through the bottom port of the Classifier Sponge Jet Feed Unit User Manual 05 Oct 06 Page 20 of 31 ooo 000 0 eee 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
4. washer lies flat in its seat Visually inspect all Blast Hose Fig E 233 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 21 and secure with safety pins or restraints Sponge Jet supplies Feed Units with a single four 4 lug Chicago fitting on a 1 25 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 B 19 with the gasket in place Connect the Blast Hose Fig E 33 and the Deadman Trigger Figure E 36 Control Lines Fig E 34 Sponge Jet supplies blast hose connections with two 2 lug Universal fittings also on 1 25 NPT nipple at the Feed Unit Fill the Feed Unit through the Hopper Fig A 2 with the desired amount and type of Sponge Media abrasive The Hopper Lid Fig A 1 must be in place prior to pot pressurization Check that the Main Air Ball Valve Fig A 14 is in the closed position and charge the supply line At the nozzle operator s command open the Main Air Ball Valve Fig A 14 verify that a minimum of 7 bar 100 psi of inbound supply air reg
5. 31 ooo 0 0 0 0 0 N Sponge Jet Feed Unit User Manual 05 Oct 06 Sponge Jet Feed Unit Requirements Equipment and Air requirements I D Inner Diameter 0 D Outer Diameter 1 Feed Unit A Compressor 7m min 250 CFM minimum at 7 6 bar 110 psi for a 8 nozzles 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 5 6 bar 80 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 6 9 5mm 3 8 5 6 336 4 8m 170 7m 250 CFM 7 11mm 7 16 6 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 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 9300 3 72mm 3 I D hose above 91m 300 Use air lines larger than the recomme
6. 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 05 Oct 06 Page 23 of 31 ooo 00 0 00 eee Figures Sponge Jet Feed Unit 85 L 240 L and 240 XL Sponge Jet Feed Unit Parts Figure A Front View 1 Hopper Lid 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 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 4 Relief Valve Optional The Relief Valve automatically releases air pressure from the pressure vessel when the internal air pressure exceeds 8 4 bar 125 psi 5 Exhaust Valve The Exhaust Valve allows air contained in the pressure vessel to escape during depressurization 6 Line Pressure Gauge Figure A 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 T Blast Pressure Gauge The Blast Pressure Gauge indicates the amount of pressure exiting the nozzle The recommended press
7. accumulated media from within it WARNING Do not operate equipment without muffler in place e Media should be stored under cover preferably under dry controlled temperature and humidity levels Refer to Sponge Media abrasive Material Safety Data Sheets 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 A 13 Remove any contaminants that have accumulated in the bowl Replace e Visually inspect the O ring on the Secondary Water Separator Fig A 13 and Moisture Separator Fig A 13 amp Fig B 22 Replace if the O ring has been damaged or worn Sponge Jet Feed Unit User Manual 05 Oct 06 Page 9 of 31 ooo o 00 0 00 eee 5 3 The following maintenance should be Maintenance continued performed monthly e Remove Auger Chain Guard Fig A 12 inspect the condition of the Auger Drive Chain Fig A 52 Apply lightweight lubricating oil as necessary then replace the 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 Sponge Jet Feed Unit User Manual 05 Oct 06 Page 10 of 31 ooo 00 0 0 0 0 eee 6 0 Troubleshooting Inevitably circumstances arise that can adversely effect the performance of the equipment The followin
8. always wear eye and hearing protection with the appropriate respiratory equipment which may depend on the type of coating or contaminate being removed 1 Prior to pressurizing the Feed Unit safety pins or restraints should be fitted at all bull hose and blast line couplings to prevent accidental disconnection 2 Before blasting all pneumatic lines should be visually inspected for holes wear and proper fit 3 The Port Hole Cover Fig B 19 must be in place and secure prior to and during operation 4 Never reach into the pressure pot area of the Feed Unit through the Hopper Fig A 2 5 Never point the Blast Nozzle Fig E 38 towards yourself or others 6 Do not remove the Auger Chain Guard Fig G 53 to the Auger while a Feed Unit is in operation Sponge Jet Feed Unit User Manual 05 Oct 06 Page 5 of 31 Sponge Jet Feed Unit User Manual 05 Oct 06 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 E 38 for wear and proper engagement of hose connections Once the Blast Nozzle bore has worn 2mm 1 16 beyond its original inside diameter it should be replaced Remove the Blast Nozzle Fig E 38 and ensure that it is equipped with a Blast Nozzle washer Replace the Nozzle and washer insuring that the nozzle
9. auger still does not rotate call Sponge Jet in the U S A 800 776 6435 207 439 0211 for further assistance Sponge Jet Feed Unit User Manual 05 Oct 06 Page 13 of 31 ooo 00 0 00 eee Troubleshooting continued 6 9 1 Air Flow Through Nozzle Suddenly Stops Troubleshooting continued 1 Stop any attempt to restart and depress the Emergency Stop Button Fig A 17 immediately Depressurize the Feed Unit and close the Main Air Ball Valve Fig A 14 2 Remove Blast Nozzle Fig E 38 from Blast Hose Fig E 33 and inspect for obstruction Remove as necessary 3 Disconnect all blast line connections and inspect for obstructions Clear as necessary 4 Remove the Auger Tunnel End Cap Fig B 23 and disconnect the blast line at the Feed Unit Check for media clog s Remove clogs if necessary Replace Auger Tunnel End Cap Fig B 23 5 Ifan obstruction occurs in the Auger Tunnel End Cap Fig B 23 area of Feed Unit rotate the Media Feed Regulator Handle Fig A 15 in a counter clockwise direction to the off position Clear the obstruction 6 Resume blasting Once a full stream of air without media is achieved slowly return the Media Feed Gauge Fig A 8 back up to the desired pressure by adjusting the Media Feed Regulator Handle Fig A 15 in a clockwise direction 6 9 2 Air Flows through nozzle but with no media and auger is rotating Note After start up media flow is not instantaneous E
10. 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 05 Oct 06 Page 22 of 31 ooo 00 0 0 eee 7 Containment Containment 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 a light 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 substanc
11. 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 05 Oct 06 Page 21 of 31 ooo 0 0 070 0 eee 6 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 providing 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 Not applicable 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 930 60 psi MFP 1 7 3 1 bar 25 45 psi Profile Generated Not applicable 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
12. Fig A 48 should increase If Auger Motor Fig G 54 sticks at startup or becomes sluggish at lower pressures it may be necessary to run pneumatic hand tool oil Note 3 through the airline to lubricate the motor The Auger motor Fig G 54 chronically starts with difficulty becomes sluggish or seizes completely it may need to be rebuilt Sponge Jet Inc offers a rebuild service Call your local distributor or representative or in the USA 800 776 6435 or 207 439 0211 for details 6 9 Auger stops rotating during normal operation 1 Stop blasting depressurize the Feed Unit close the Main Air Ball Valve Fig A 14 and depress the Emergency Stop Button Fig A 17 2 Remove the Auger Chain Guard Fig G 53 amp A 12 and Auger Drive Chain Fig G 752 3 Try spinning the Auger Sprocket Fig G 49 and the Auger Motor Sprocket Fig G 48 by hand A f Air Motor Sprocket Fig G 48 will not turn by hand call Sponge Jet for technical assistance at 800 776 6435 or 207 439 0309 B If the Auger Sprocket Fig G 49 will not turn by hand e Remove the Auger Fig G 50 and the Auger Tunnel End Cap Fig G 51 Clear the sponge and or foreign debris from the Lower End Assembly e Replace the Auger Fig G 50 the Auger Tunnel End Cap Fig G 51 the Auger Drive Chain Fig G 52 and Auger Chain Guard Fig G 53 and restart the blasting process Return the media feed pressure to its desired level between 1 4 bar 10 60 psi If the
13. Pneumatic Classifiers are also available See separate Operator Manuals for each Sponge Jet Electric and Pneumatic Classifier 3 Recommended Tools 6 Pliers 10 Channel Locks Screw Drivers Regular and Phillips 10 T handle Hex Key 9 64 and 3 16 10 Adjustable Wrench Wrenches 1 2 9 16 5 8 3 4 and 11 16 Small Hammer 12 Pipe Wrench Grease gun and grease Pneumatic tool oil WD 40 or equivalent Sponge Jet Feed Unit User Manual 05 Oct 06 Page 19 of 31 ooo 00 0 0 0 00 eee 4 Recommended Spare Parts available from Sponge Jet 1 1 4 muffler 1 Air motor 1 Auger 3 Nozzle washers 3 Hose washers 1 Hose repair kit for control lines 1 Automatic drain Kit 1 0 ring for 1 25 main air water separator 1 Norgren actuator valve 1 timer 3 ft 5 32 pneumatic hose 3 ft 3 8 pneumatic hose 5 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
14. Sponge Jet Sponge Blasting System Sponge Jet Feed Unit User Manual Model 85L 150L 240L 240XL Sponge Jet Inc USA Sponge Jet Europe Ltd 2322533350 235 Heritage Ave Suite 2 Robson Way Blackpool D Portsmouth NH 03801 United Kingdon FY3 7PP tel 603 431 6435 tel 44 0 1253 390731 www spongejet com SPONGE scoe a Sponge Jet Feed Unit User Manual 05 0ct 06 Page 1 of 31 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 05 Oct 06 Page 2 of 31 ooo 0 0 0 0 0 SEEN 1 1 Warning 1 The use of bleeder type deadman valves can 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 recommend
15. Trigger is released 18 Exhaust Valve Cover The Exhaust Valve Cover secures the Exhaust Valve Diaphragm during operation of the Feed Unit Figure D Internal View 29 Actuator Tree Assembly The Actuator Tree Assembly agitates sponge media in the pressure vessel 30 Pop Up Valve The Pop Up Valve seals the pressure vessel during blasting 31 Media Actuator The Media Actuator is a pneumatic motor that turns the actuator arm assembly inside the pressure vessel The media actuator assists in providing a continuous sponge media supply during blasting 32 Actuator Chain The Actuator Chain assists in movement of media through the pressure vessel 33 Lower End Assembly The Lower end Assembly houses the Auger Refer to Figure G on page 29 Page 27 of 31 Figure E Deadman Trigger Assembly 33 Blast Hose The Blast Hose conveys the media from the Pressure Vessel to the Nozzle 34 Control Line The Control Line flows the pneumatic circuit of air from the Deadman to the Aquamatic Valve 35 Clean Out Screw The Clean Out Screw provides maintenance access to the internal Figure E components of the Deadman Trigger 36 Deadman Trigger The Deadman Trigger allows for on or off operation of the Deadman System 3T Nozzle Connector The Nozzle Connector connects the Nozzle to the Blast Hose 38 Blast Nozzle The Blast Nozzle is an acceleration tip designed to focus the blasting media at a desired l
16. ability are important safety precautions that must be utilized when disconnecting any high pressure air supply line e lf the Feed Unit is to remain out of service for more than one day remove by vacuum all residual media from the Feed Unit or the Hopper Fig A 2 through the Port Hole Fig B 19 e The resulting product of process dependent on use must be disposed of in accordance with local and or Federal regulations governing hazardous waste disposal Sponge Jet Feed Unit User Manual 05 Oct 06 Page 8 of 31 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 E 38 for wear Once the nozzle bore has worn 1 16 2mm beyond its original intended diameter it should be replaced e Remove the Blast Nozzle Fig E 38 and ensure that it is equipped with a nozzle washer between the nozzle and its holder Replace the nozzle and washer taking care to see the washer in its holder e Visually inspect all Blast Hose Fig E 33 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 Remove the Exhaust Muffler Fig C 3 Remove any
17. d to clean E out the Feed Unit The choke valve in the closed position causes sponge Figure B media to quickly exit the Feed Unit 25 same as part 5 on the front view 26 same as part 3 on the front view 27 Pressure Vessel The pressure vessel is where sponge media is stored during blasting 28 Clean 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 29 Crab Assembly 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 05 Oct 06 Page 26 of 31 Figure C Figure D Sponge Jet Feed Unit User Manual 05 Oct 06 Figure C Exhaust System 3 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 4 Relief Valve Optional The Relief Valve automatically releases air pressure from the pressure vessel when the internal air pressure exceeds 8 4 bar 125 psi 5 Exhaust Valve The Exhaust Valve allows air contained in the pressure vessel to escape during depressurization 17 Exhaust Valve Diaphragm The Exhaust Valve Diaphragm regulates the release of air pressure from the Feed Unit when the Deadman
18. e airstream and the Auger is rotating 1 Adjust the panel to the Non Blasting Mode 6 9 5 2 Remove top orange output airline on the Internal Panel Filter Fig F 39 depress the Deadman Trigger Handle Fig E 36 and check for airflow from top of Internal Panel Filter Fig E 39 which should be continuous Sponge Jet Feed Unit User Manual 05 Oct 06 Page 15 of 31 Troubleshooting continued Sponge Jet Feed Unit User Manual 05 Oct 06 6 9 7 If no airflow is felt from the top of the Internal Panel Filter Replace the Internal Panel Filter Cartridge with Spare Sponge Jet Filter Cartridge Fig F 44 held inside Panel when replacing the filter it is necessary to switch airline fittings from old filter to new Re test for airflow and check for proper motion of the Agitation Indicator Eye Fig A 9 When operating properly a light pulse of air can be felt exiting from the top of the Timer Fig F 40 Resume blasting 6 9 8 If no pulse of air is felt at the top of the Timer 1 Check that Timer Fig F 40 is set properly at 75 for 85L and 1 75 for 240L XL Reset if necessary Test for pulse of air and check for proper motion of the Agitation Indicator Eye Fig A 9 and Actuator Tree Assembly Fig D 29 Resume blasting 6 9 9 If no pulse of air is felt at the top of the Timer once it has been set to 75 or 1 75 Remove the 2 screws on face of timer and replace the timer available from Sponge Jet Inc
19. ed Unit will not stop running 1 Depress the Emergency Stop Button Fig A 17 on the Control Panel Fig F 2 Once Feed Unit has stopped running with the Deadman Trigger Handle Fig E 36 still not depressed pull the Emergency Stop Button Fig A 17 out After assuring that compressed air and abrasives from the Nozzle cannot do damage or injury listen for exhausting air coming from the Deadman Trigger Handle area Fig E 36 Sponge Jet Feed Unit User Manual 05 Oct 06 Page 12 of 31 ooo 00090 00 eee Troubleshooting continued 3 Ifa continuous leak of air is heard from the Deadman Trigger Handle Fig E 36 then reverse quick connect fittings at Feed Unit end of the control line re test according to Section 4 0 and start 6 7 Deadman Trigger Handle Fig E 36 is exhausting air while in shutdown condition 1 Reverse quick connects at Feed Unit end of control line 2 Ifthe Deadman Trigger Handle Fig E 36 is still leaking remove Clean Out Screw Fig E 35 in Deadman Trigger Handle Fig E 36 Check for debris within the Deadman Handle clean and replace 6 8 Auger will not begin rotating 1 First check that the Media Feed Gauge Fig A 8 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 Regulator Handle Fig A 15 in a clockwise direction The pressure level of the Media Feed Gauge
20. ed pressure is not only dangerous but may also damage the pressure regulations 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 drain offs must always be slightly open to allow water to escape 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 Sponge Jet Feed Unit User Manual 05 Oct 06 Page 3 of 31 EEN SSS 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 utilizing the fork pockets will result in unstable operation and unpredictable load shifts and possible dama
21. es 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 The better the containment and initial cleaning the less time spent preparing Sponge Media abrasive for reuse and cleaning up when the job is finished 8 Safety Operation of the Sponge Jet system necessitates the use of certain safety equipment Because the Sponge Blasting System is an industrial 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
22. g 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 In case of difficulty call your local distributor or representative Technicians are available 24 hours a day 365 days a year by calling the U S A 800 SPONGEJET 800 776 6435 or 207 439 0211 6 1 Feed Unit will not run 1 Check that Main Air Ball Valve Fig A 14 is open 2 Check that Emergency Stop Button Fig A 17 is not pushed in 3 Check that the Control Line Fig E 34 connections at the Feed Unit and at the Deadman Trigger Fig E 36 handle are secure 4 Check for holes or other damage in the full length of the Control Lines Fig E 34 and repair as necessary 5 Check that the Line Pressure Gauge Fig A 6 registers adequate pressure If necessary turn on or charge the compressor 6 Test Feed Unit for proper operation 6 2 If the Feed Unit will still not run 1 Depress and then release the Deadman Trigger Handle Fig E 36 with the Main Air Ball Valve Fig A 14 open and the Feed Unit pressurized 2 Listen for an exhaust of air from behind the Deadman Trigger Handle Fig E 36 when this handle is released 6 3 If an exhaust of air is not heard at the Deadman Trigger handle 1 Close the Main Air Ball Valve Fig A 14 2 Remove the red tubing line from the right side of the Aquamatic Va
23. ge and or injury Overhead Lifting The Sponge Jet Feed Unit is equipped with four lift eyes at the top of the frame intended for use with a proper lift set The frame is designed for a maximum gross mass of 771 kg 1 700 Ib WARNING The frame design intends the use of all four lifting eyes for lifting 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 05 Oct 06 Page 4 of 31 ooo 00 0 00 eee 3 0 Safety Note 1 125 psi 8 6 bar The Sponge Jet Inc Feed Unit is a pressurized positive air feed system sustained maximum Only certified operators should adjust maintain and repair this equipment inbound pressure Sponge Jet offers a certification program to train operators in the mechanics of the equipment as well as in Sponge Blasting applications e Before performing any maintenance on the Feed Unit make sure equipment is off and depressurized The Main Air Ball Valve Fig A 14 and the Emergency Stop Button Fig A 17 on the Control Panel should both be in the off position to insure the Feed Unit is not accidentally pressurized e 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 on the Feed Unit panel gauge marked Blast Pressure Fig A 7 e When operating the Feed Unit people in proximity should
24. ghten as necessary 2 Remove Exhaust Valve Cover Fig C 18 and inspect for obstructions and check inner gasket for rips or any small holes Clean or replace as necessary 6 9 5 Panel testing in the non blasting mode This procedure will help to diagnose possible component problems in the Panel and in the Actuator system within the Pressure Vessel This special diagnostic activity should only be performed by Certified Operators or under the direct guidance of a Sponge Jet Technical Service Representative 1 Turn the Blast Pressure Regulator Handle Fig A 16 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 Regulator Handle Fig A 15 counter clockwise to the off position by rotating the handle until the handle is removed from the body of the valve Remove Port Hole Cover Fig B 19 and evacuate enough abrasive media in the Pressure Vessel so that the Media Actuator Fig D 31 and the Actuator Tree Assembly Fig D 29 can be clearly 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 45 degrees alternating direction every 1 2 seconds The components do not rotate beyond 45 degrees 6 9 6 Air flows through Blast Nozzle but with no media in th
25. isters on the Line Pressure Gauge Fig A 6 on the Feed Unit Internal Control Panel Fig F Page 6 of 31 ooo 00 0 000 eee Operation amp Shutdown After the operator depresses the Deadman Trigger Figure E 36 allow the continued Feed Unit to pressurize This may take 5 to 10 seconds CAUTION Do not cycle the Deadman Trigger while waiting for abrasive at the Nozzle as in conventional abrasive blasting Cycling the Deadman Trigger will usually clog the Blast Nozzle and Blast Line Once the Inbound Pressure Gauge Fig A 6 Blast Pressure Gauge Fig A 7 and the Media Feed Gauge Fig A 8 have stabilized in operation adjust the Blast Pressure Adjustment Handle Fig A 16 and the Media Feed Adjustment Handle Fig A 15 to the desired levels Clockwise inward adjustments increase pressures Do not exceed a Blast Pressure Gauge Fig A 7 reading of 6 bar 85 psi note 2 Adjust the Media Feed Gauge Fig A 8 to the desired level usually 2 8 bar 40 psi for initial operation using the Media Feed Adjustment Handle Fig A 15 Confirm that the Blast Pressure Gauge Fig A 7 remains at the desired level Once the desired Blast Pressure Gauge Fig A 7 and Media Feed Gauge Fig A 8 levels are obtained visually confirm that the Auger Shaft Fig G 50 is rotating and that the Agitation Indicator Eye Fig A 9 is functioning These levels should remain constant unless adjusted
26. lve Fig A 10 3 Slightly open the Main Air Ball Valve Fig A 14 and listen for a leak of air from the Aquamatic Valve Fig A 10 Sponge Jet Feed Unit User Manual 05 Oct 06 Page 11 of 31 ooo 000 0 ee Troubleshooting continued 6 4 If no air is heard coming from the Red tubing line on the right side of the Aquamatic Valve 1 Check for obstructions in the supply line from the compressor to the Feed Unit 2 Checkthat compressor is on and that the bull line is charged with air 3 Re test the Deadman Trigger Handle Fig E 36 4 Resume blasting 6 5 If an exhaust of air is heard at the Deadman Trigger Handle when the Deadman Trigger Handle is released 1 Remove the Red Air Line from the Exhaust Valve Fig C 5 amp Fig A 5 2 While holding the Red Air Line securely depress the Deadman Trigger Handle Fig E 436 and feel for a blast of air at the Red Air Line 6 5 1 If air is felt flowing through Red Air Line 1 Stop flow of air from red line by placing thumb over that line This will test for a possible ruptured exhaust valve diaphragm 6 5 1a If Feed Unit then starts up 1 Remove thumb from red line Red Air Line 2 Replace Exhaust Valve Diaphragm Fig C 17 3 Resume blasting 6 5 1b If Feed Unit does not start up and an air leak is exhausting from Aquamatic Valve Exhaust 1 Replace Aquamatic Valve Fig A 10 gasket 2 Resume blasting 6 6 At initial start up the Fe
27. mount of media provided to the airline for blasting Rotating the handle to the right or clockwise will increase the amount of media delivered to the airline Rotating the handle to the left or counter clockwise will decrease the amount of media delivered to the airline 16 Blast Pressure Regulator Handle The Blast Pressure Adjustment Handle allows for the adjustment of airflow to the Blast Nozzle 17 Emergency Stop Button The Emergency Stop Button stops the Feed Unit instantly when depressed 18 Lifting Lug The lifting lugs are used to properly attach lifting slings to the Feed Unit Sponge Jet Feed Unit User Manual 05 Oct 06 Page 25 of 31 Figure B Rear View 19 Port Hole Cover The Port Hole Cover allows access to the inside of the pressure vessel 20 Forklift Pockets The Forklift Pockets allow the Feed Unit to be lifted or moved with a forklift 21 Blast Line Connection The Blast Line Connection is a two pronged universal blast line connector fitting which allows for connection from the blast line to the Feed Unit 22 Moisture Separator The Moisture Separator which automatically drains when full protects the air motor from excess moisture 23 Auger Tunnel End Cap The Auger Tunnel End Cap allows access to the auger for cleaning purposes 24 Choke Valve when present The Choke Valve is normally fully open The Choke Valve when closed directs the air stream through the Pressure Vessel and can be use
28. nded whenever possible C Fittings With 32mm 1 25 to 51mm 2 I D hose use 32 38mm 1 25 1 5 I D Universal 4 Lug Air Coupling With 51mm 2 and larger use Boss Fittings Page 18 of 31 I eee D Blast Lines Sponge Media abrasive has been successfully blasted through 91m 300 of final blast line 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 Up to 915m 50 of 75 or 1 19mm or 25mm I D Whip Blast Hose connected to Upto 30m 100 of minimum 32mm 91 25 I D Blast Hose which may be further connected to Upto an additional 100 30m of minimum 38mm 1 5 Blast Hose Blast Hose lengths above 91m 300 are not recommended Note No electricity is required to run Feed Units 2 Electric Media Classifier 1 The Electric Media Classifier requires a 115 volt 20 amp dedicated circuit Appropriate heavy gauge extension cords need to be used to support the above electrical requirements It should be noted that long lengths of extension cord may lessen the voltage from the supply as delivered to the classifier causing increased amperage draw heat and resulting tripped circuits and even electrical damage to the classifier motor Always use the shortest amount of extension cord as possible and with proper capacity Note Sponge Jet
29. ocation for blasting activities Sponge Jet Feed Unit User Manual 05 Oct 06 Page 28 of 31 Figure F Internal Control Panel Sponge Jet Feed Unit User Manual 05 Oct 06 39 Internal Panel Filter The Filter removes vapor level moisture from the pneumatic Timer Circuit 40 Timer The Timer is a pneumatic timing mechanism that regulates the delay interval of the Actuator s motion 41 Auger Instant Off The Auger Instant Off system immediately vents the Air Motor and stops the flow of media through the Feed Unit as the operator releases the Deadman or the Emergency Stop System is activated 42 Exhaust Muffler The Exhaust Muffler relieves pressure associated with various systems on the Feed Unit 43 Agitation Control Valve The Agitation Control Valve provides the pneumatic signal that activates the Actuator Tree Assembly Page 29 of 31 I eee 44 Internal Panel Spare Filter The Spare Filter replaces 39 45 External Panel Muffler if mounted The Ext Panel Muffler vents signal air from the Actuation System 46 Internal Panel Filter Output Line The Filter Output Line is the outbound connection of the Vapor Filter 4T Internal Panel Filter Input Line The Filter Input Line is the inbound connection for the air supply to the vapor Figure G Lower End Assembly 48 Auger Motor Sprocket The Air Motor Sprocket drives the Auger Drive Train 49 Auger Sprocket The Auger S
30. procket drives the Auger 50 Auger Shaft The Auger Shaft meters Sponge Media abrasive into the air stream 51 Auger Tunnel End Cap The Auger Tunnel End Cap allows access to the far end of the Auger 52 Auger Drive Chain The Auger Drive Chain in conjunction with the Auger Sprocket rotates Figure G the Auger Shaft 53 Auger Chain Guard The Auger Chain Guard protects the Air Motor Sprocket and the Auger Drive Chain 54 Auger Motor The Air Motor through adjustment at the control panel regulates the air media mixture by turning the Auger Shaft Sponge Jet Feed Unit User Manual 05 Oct 06 Page 30 of 31 NOTES MODEL SERIAL Sponge Jet Feed Unit User Manual 05 Oct 06 Page 31 of 31
31. ure for effective coatings removal and optimal media reuses is 5 9 bar 85 psi or less 8 Media Feed Gauge The Media Feed Gauge indicates the amount of air pressure being supplied to the Media Feed 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 Sponge Jet Feed Unit User Manual 05 Oct 06 Page 24 of 31 9 Agitation Indicator Eye The Agitation Indicator Eye shows the rate at which the Sponge Jet Actuator Tree Assembly is actuating within the pressure vessel 10 Aquamatic Valve The Aquamatic Valve serves as the Feed Unit s on off switch When the Aquamatic Valve is open blasting is initiated When the Aquamatic is closed the Feed Unit is depressurized and turns off 11 Blast Pressure Regulator The Blast Pressure Regulator regulates the amount of airflow traveling through the Feed Unit and out to the nozzle 12 Auger Chain Guard The Auger Chain Guard prevents injury from contact with the drive chain 13 Secondary Water Separator The Secondary Water Separator separates water from the air stream with an 80 micron filter 14 Main Air Ball Valve Figure A repeated The Main Air Ball Valve starts and stops the airflow from entering the Feed Unit This device is not a regulation device 15 Media Feed Regulator Handle The Media Feed Adjustment Handle allows the pot tender to regulate the a
32. ven with only 50 of final blast line 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 if necessary 2 While the Feed Unit is in operation check that the Agitation Indicator Eye Fig A 9 is blinking from green to black every few seconds while machine is pressurized and operating If the Agitation Indicator Eye Fig A 9 is not changing call Sponge Jet for technical assistance in the U S A at 800 776 6435 207 439 0211 3 After depressurizing the system in accordance with Section 4 2 open the Port Hole Cover Fig B 19 and check that Actuator Tree Assembly Fig D 29 is attached to Media Actuator Fig D 31 Reconnect if necessary 6 9 3 Too much media exits the Nozzle and or media is pulsing out of nozzle 1 Check that the Choke Valve Fig B 24 is in full open position e g parallel to pipe Open if necessary and continue 2 Check the Media Feed Gauge Fig A 8 is not set above 3 4 Bar 50 psi if so reduce the pressure as necessary Sponge Jet Feed Unit User Manual 05 Oct 06 Page 14 of 31 AE ee Troubleshooting continued 6 9 4 Blast Pressure increases and decreases continuously or Feed Unit exhausts intermittently while blasting 1 Check for holes in Control Lines Fig E 34 and check for air leaks at all fitting connections Repair replace or ti
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