Safe-man 2 Manual
Contents
1. vin E 1 1 I n F j Ty aF i 1 d i f F F gt mm Replace old Green Tubing Cut new Green Tubing to with new Green Tube needed length Control Panel PULL P 9 AN Insert new Green Tubing Insert leftover new Green Insert the other end from Feed Unit Control X Tubing into Signal Air of new Green Tubing Panel into Supply fitting of Abrasive Control into fitting that leads to of Abrasive Control Solenoid Valve of Safe Feed Unit Auger Motor Solenoid Valve on man Control Panel Safe man Control Panel Pull tube out Cut excess Green Tubing if desired Safe man User Manual 5 August 2010 Page 10 of 19 4 7 Connecting Control Panel Customized Connection The Safe man controls pneumatic solenoid valves which send signals to the blast vessel Solenoid valves can be customized to accommodate the on off or off on requirements of other non Sponge Jet blast vessels This unit is factory configured to work with Sponge Jet Feed Units and works with most other units Use Figure 2 to match the air signal function to the desired function of your blast vessel Figure 2 Safe man Solenoid Schematic Safe man Back View Deadman Solenoid Abrasive Shut off Solenoid Air Relief Bleed Control D2 ll Control M2 typically plugged typically plugged Control 01 Control M1 Supply Deadman2. 4 4 Connecting Control Panel Cables Safe man User Manual 5 August 2010 Page 8 of 19 4 5 Connecting Control Panel In line Deadman Valve Connect yellow twinlines where pneumatic Deadman typically connect If system architecture and fittings are not the same see section 4 7 Connecting Control Panel Customized Connection Sponge Jet Models ONLY 4 6 Connecting Control Panel Abrasive Control Valve BEB RRB RP RRR REPRE Re eee eee eee Figure 1 Feed Unit Set up Schematic Feed Unit New Green Pneumatic Tubing Control Panel cut each section to length Old Green Pneumatic Tubing Disconnect from fittings at both ends and leave in place Safe man Control Panel New Yellow Twinline from Safe man Control Panel Green Gorilla Cable Old Yellow Twinline amp Deadman Disconnect and store for troubleshooting Safe man Control Pad y Safe man User Manual 5 August 2010 Page 9 of 19 4 6 Connecting Control Panel Abrasive Control Valve continued For Sponge Jet Models ONLY 1 Locate Green Tubing which connects to Feed Unit Auger Motor 2 Disconnect Green Tubing do not discard Feed Unit 3 Follow Green Tubing to Feed Unit Control Panel disconnect it Control Panel do not discard Feed Unit Auger Motor UN i 4 GotoStepb am A 1 How to Disconnect Pneumatic Tubing p 4 i 4 L rl
3. Systems are designed to operate with Sponge Jet Feed Unit s and other conventional abrasive blast vessels Unit functionality depends on functionality of the abrasive blasting vessel This unit is designed to operate up to 91m 300 ft from the abrasive blasting vessel This unit provides three basic functions E LED Nozzle Light RY In line Deadman functions as on off control of blast vessel Qu Blast mode setting switches between blasting with air only air wash and blasting with air and abrasives normal blasting TO UTILIZE THIS FUNCTION THE ABRASIVE BLAST VESSEL OR MUST HAVE THIS PNEUMATIC CONTROL FEATURE NOTE all Sponge Jet Feed Unit models have this feature 3 2 Power Requirements This unit can operate with either AC or DC power supply AC operating range is 90 264 volts 4 63Hz 80watts DC operating range is 10 15 volts 10amp 120watts Note DC is typically connected to compressor battery with an adequate sized alternator Safe man User Manual 5 August 2010 Page 6 of 19 5555 _______________________ 4 0 Installation 4 1 Grounding prevent electrostatic buildup possible electric discharge harm the unit or to the operator the unit must ALWAYS be properly grounded bonded Safe man User Manual 5 August 2010 Page 7 of 19 4 3 Connecting DC Power DC Power Wire Gauge Requirements Up to 7 5m 250 14 pt 15m S Up to 28m 75
4. IN LINE DEADMAN VALVE MODE ON OFF A IVE CONTROL VALVE 24 Supply Air BLAST MODE ON OFF 25 Abrasive Solenoid Valve 26 Supply Air 27 Signal Air Abrasive Control NS A N d T z v PU Safe man User Manual 5 August 2010 Page 4 of 19 2 0 Safety Checklist o This Unit contains electrical and pressurized components which control a pressurized system Only trained operators should adjust maintain and repair it o Besure to observe all applicable safety requirements from the blast unit manufacturer as well as industrial local state province and government regulations o Inbound pressure should never exceed 8 6bar 125psi o To prevent electrostatic buildup and possible electric discharge the unit must be grounded at the black DC Power Terminal o Operators and people in proximity to blasting should always wear eye and hearing protection with appropriate respiratory equipment and clothing which may depend on the type of coating or contaminant being removed o Improper configuration and installation may cause unintentional start up and can result in personal injury Contact Sponge Jet Technical Services at techservices spongejet com 1 603 610 7950 for assistance o This unit is not designed to operate in heavy rain snow or temperature extremes Safe man User Manual 5 August 2010 Page 5 of 19 3 0 Requirements 3 1 Equipment Requirements safe man
5. in an appropriate manner for operation Inspect all Blast and connections Repair or replace worn damaged components Ensure all couplings are equipped with coupling gaskets safety pins and hose restraints and all are properly installed Insure blast vessel its hoses and Safe man black DC port are properly grounded Mains Power LIGHT Indicates Mains AC Indicates LED Power is connected SPONGE iif Safe man Nozzle Light is properly OR CONTROL PANEL connected and operating POWER SUPPLY E DC Battery Power NOZZLE Indicates Battery Indicates Control Pad is Power 12 volt DC BLAST AIRONLY STANDBY ume rm ag properly connected is connected BLAST AIR ONLY STANDBY Indicates Air and Indicates Air only is Indicates neither Air Abrasives are exiting exiting Nozzle nor Abrasives and Air the Nozzle are exiting the nozzle Safe man User Manual 5 August 2010 Page 14 of 19 man Control Pad Operation Figure 2 Safe Green Safety Switch and Indicator Light Indicator lights Indicator lights In line Deadman TE Air Only Mode Connection to a powered control box Air and Abrasives Mode ON OFF T Blast Mode Activated itch Toggles Abrasive Cut off Valve ON OFF Also deactivates Deadman Off Heg dol CONTROL PATENT PENDING 20
6. 09 Sponge Jet inc All rights reserved M R USING THE CONTROL PAD As a Deadman Press and Hold to Blast Press and Press Switch and Release toggles Release between ON OFF of abrasive shut off valve Green Safety Safe man User Manual 5 August 2010 Page 15 of 19 6 0 Maintenance Routine maintenance is required to provide long and reliable equipment life This Unit must be shut down and disconnected prior to conducting maintenance Prior to each use e Inspect all hoses cables connections and buttons for excessive or abnormal wear and damage e Inspect Protective Lens Cover for damage Safe man User Manual 5 August 2010 Page 16 of 19 If sensitivity of Deadman changes e Reset In line Deadman pressure by removing and reinserting the cap on In line Deadman Equalizing Valve Safe man User Manual 5 August 2010 Page 17 of 19 7 0 Troubleshooting No nozzle output when Check Control Panel indicator Nozzle light is illuminated depressing In line Deadman and triggering press and release Green Check connections from Control Pad to In line Deadman and Gorilla Cable extensions Safety Button If Control Panel indicator has power but Nozzle light is NOT illuminated If Control Panel Indicator Nozzle light is illuminated and Control Panel indicator lights work when switches are depressed inspect replace solenoid Confirm In line Deadman Equalizing Val
7. Safe man Productivity System Safe man 2 0 Safe man Sponge Jet Inc 235 Heritage Ave Suite 2 Portsmouth NH 03801 USA 1 603 610 7950 www spongejet com PRODUCTIVITY SYSTEM Safe man User Manual 5 August 2010 Table of Contents Section Page 1 0 Introduction 3 2 0 Safety Checklist 5 3 0 Requirements 6 4 0 Installation 7 5 0 Operation 14 6 0 Maintenance 16 7 0 Troubleshooting 18 Notes 19 IMPORTANT NOTE While parts systems components operational procedures may be the same between equipment models the images provided in this manual may vary from model to model 1 0 Introduction Basic Components 1 Control Panel 2 Nozzle Holder not included 3 Control Pad 4 Nozzle not included 5 LED Light Assembly 6 Protective Lens Cover 7 Mounting Screw 8 O Ring 9 Green Tubing 10 In line Deadman 11 Neoprene Sleeve 12 In line Deadman Equalizing Valve 13 Gorilla Cable extensions sold separately 14 Hanging Bracket 15 Control Panel Power Mains Plug Safe man User Manual 5 August 2010 Page 3 of 19 Control Panel front view Basic Components continued 16 Control Panel front view 17 DC Power Terminal 18 Mains AC Power Socket 19 Feed Unit Socket Solenoid Valves 20 Deadman Control Socket Control Panel back view 21 Control Panel rear view 22 Deadman Solenoid Valve 23 Signal Air Deadman Blasting as HENENENEEHEEENH
8. Solenoid i Control D1 Control D2 In line Deadman Function rah Activated ON Blast Mode Air Signal No Air Signal Inactivated OFF Not Blasting No Air Signal Air Signal shut Down no power No Air Signal Air Signal Abrasive Shut Off Valve Control M1 Control M2 Shut Down no Power Down Shut Down no Power Power No Air Signal Air Signal Safe man User Manual 5 August 2010 Page 11 of 19 4 8 Assembling Control Pad and In line Deadman NOTE Adjust Safe man Neoprene Sleeve to lay flat NEVER locate In line Deadman on inside curve of blast hose CAUTION Never use Safe man when In line Deadman has severe creases or folds This condition can uncontrollably activate blasting Optional for infrequent nozzle changes Safe man User Manual 5 August 2010 Page 12 of 19 4 8 Assembling Control Pad and In line Deadman continued Open and close Deadman Equalizing Valve To Safe man To Safe man Control Pad Control Panel One end of Gorilla Cable The other end of Gorilla Cable plugs into Gorilla Cable leading to Safe man plugs into Safe man Control Pad Note additional Gorilla cable extensions can be added as needed Safe man User Manual 5 August 2010 Page 13 of 19 5555 5 0 Operation Before Operating the Safe man Verify the Feed Unit Y blast vessel is properly setup and operating correctly as directed by manufacturer Verify that unit is secured
9. ve is tightly mounted check for obstructions check rubber seal If necessary remove clean replace insert and re tighten LED Nozzle Light shuts This is normal operation IF Safe man has been sitting without air flow from blasting off or blinks slowly To remain cool in absence of air flow LED Nozzle Light shuts down intermittently protecting it from overheating If LED Nozzle Light flashes during blasting and the nozzle is mounted properly at end of the nozzle inspect for loose connections to light Safe man User Manual 5 August 2010 Page 18 of 19 NOTES MODELS SERIAL Safe man User Manual 5 August 2010 Page 19 of 19
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