Pulsar III-P & VI-P Pressure Cabinet
Contents
1. 01352 CT 4 1 4 OriGene a 01353 Hose assembly 1 x 42 exhaust 23916 Bushing 1 4 x 1 8 NPT u ececceeceeseeees 02010 Hose assembly cpld 1 pusher line 22508 Adaptor el 1 4 male NPT x 3 8 tube 11685 Adaptor str 1 4 male NPT x 3 8 tube 11736 Nozzle washer pkg Of 10 essee 21580 Muffler 1 exhaust eeen 05068 9 N30 Some Items Rotated For Clarity Figure 20 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 9 8 Item TPO N OMOT R CON a l PULSAR III P III PE and VI P VI PE PRESSURE CABINETS Reclaimer Figure 21 Description Stock No Reclaimer VI P includes items Through 8 oo ecceecctceeseeeesteeessseeeeeeeens 21801 Inlet adaptor for 5 hose standard use cccceeees 12361 for 4 hose steel media ceeeee 12350 Gasket inlet adaptor 00 ceeeeneeeeees 11779 Outlet adaptor eeeeeeeeceeeeeesteeeeneeteees 20344 Gasket COOP cccccccecccssesscecetsrerereteeees 11745 Debris screen cccccceceeeeeeeeeeeceeeteeteeeeees 21265 Door assembly ACCESS ceeeceeessteeeeeees 14271 Latch assembly door sses 12263 Wear plate cceeecceeeeeseeeeeeeeeseteeeeneeeeees 13011 Hose 5 light lined flex 7 ft required 12467 Clamp 5 NOSE oora eraa aa 11578 Gasket 5 16 x 1 adhesive backed 4 ft required assesses 00187 Clamp 6 NOSE iriser aa 00750 Hose 6 flex 4 ft req2. 7 8 Seasoning Cartridges 7 8 1 New cartridges must be seasoned Cartridges are seasoned by letting a dust cake develop on the filter media before starting the pulsing cycles 7 8 2 To stop the pulse turn the pulse regulator off to 0 psi 7 8 3 Operate the cabinet without pulsing for about two hours or until visibility decreases which ever comes first At that time turn the pulse regulator to 60 psi to start the pulsing cycle 7 9 Pop up Valve Replacement Figure 12 7 9 1 Empty the machine of media as described in Section 4 2 3 7 9 2 Depressurize the blast machine and lockout and tagout the air supply A WARNING Failure to observe the following procedure before performing any blast machine maintenance could cause serious injury from the sudden release of compressed air Depressurize the blast machine Lockout and tagout the compressed air supply Bleed the air supply line to the blast machine 7 9 3 To gain access to the pop up valve remove the inspection door assembly Page 14 i es Pop up Valve Pop up Guide Loosen J a INN Figure 12 7 9 4 Using a small pipe wrench unscrew the pop up valve guide by turning it counterclockwise Remove the pop up valve and guide from the machine Place the new pop up valve in the guide and screw the valve guide with the pop up valve in it back into position inside the machine Tighten the guide so it is snug but not wrench tight 7 9 5 Put
3. S Figure 18 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 9 6 Item on gt Plumbing and Control Line Assembly Figure 19 Description Stock No Valve 3 Way sretan aieka ae aaie aiana 12202 Adaptor 1 8 NPT x 1 8 barb 00 11732 Tubing 1 8 ID urethane specify ft required 2 eee eeesteeeeees 12475 Tubing 1 8 ID twin urethane specify ft required cceeeeesteeeeeees 19577 Adaptor straight 1 4 male NPT x 3 8 tube ee 11736 Tubing 3 8 OD poly specify ft required 12478 Tee 1 8 tube barb eee cecceeeeeeee eens 11734 Filter 1 auto drain ou eee ceceeeeseeeeeeeeeeees 22425 Regulator with gauge 1 4 oe 12050 Valve 4 way air eeeeeeceeeeseceeeeeeeeeeeeeneees 12203 Adaptor elbow 1 4 male NPT x 3 8 tube 11685 Outlet valve 1 diaphragm e 03371 Nipple 1 4 brass hex s es 02808 X Page 21 14 Elbow 1 4 brass St sseenseeeeneee neeese 02027 15 Bushing 1 4 x 1 8 NPT asssesesssennsnennen 02010 16 Hose assembly 1 x 42 exhaust 23916 17 Muffler 1 4 DrONnZe ceeeeeeeeeeeeteeeeeees 03988 18 Adaptor 1 2 NPT x 1 2 male flare 11351 19 Hose end 1 2 barb x 1 2 female swivel 15002 20 Hose end 1 2 barb x 3 8 male NPT 06369 21 Blow off nozzle ceeecseseceesteeee
4. pressing it tightly to bond Trim the gasket to fit and compress the ends to seal 7 4 5 Using 5 32 thick strip gasket repeat the process on the window frame 7 4 6 Trim around the window frame bolts slots as needed 75 Window Frame Removal Figure 8 7 5 1 Remove the two window frame nuts located on the upper edge of the window frame and swing the window frame open 7 5 2 Remove the window to prevent breakage 7 5 3 Pivot the window frame up or down until tension is off the frame hinges 7 5 4 To remove slide the frame to the right The hinges separate as shown in Figure 8 Page 12 Pivot the frame up or down until tension is removed from the hinges Slide the frame to the right to separate the hinges Figure 8 7 5 5 Replace the frame in reverse order Align the top bolt holes with the bolts slide the frame as necessary 7 5 6 Set the window squarely over the window opening ensuring that all edges of the window are centered and overlapping the window gasket and resting on the lower locators 7 5 7 Swing the window frame into place and tighten the frame nuts 7 6 Light Assembly CAUTION Use an approved step ladder when servicing the light assembly Do not climb on top of the cabinet The cabinet top will not support the weight of a person 7 6 1 Shut off electrical power 7 6 2 Gasket Replacement 7 6 2 1 Remove the four holding wing nuts and use the handles to lift the fixture o
5. 5 7 3 2 Remove the old window 7 3 3 Inspect the window frame gaskets both on the window frame and on the cabinet If either gasket is damaged replace it per Section 7 4 7 3 4 Install optional view window cover lens per Section 6 5 7 3 5 Set the new window cover lens down squarely over the window opening ensuring that all edges of the window are centered and overlapping the window gasket and that the window is resting on the lower locators 7 3 6 Swing the window frame into place and tighten the frame nuts 7 4 Window Gasket Replacement Figure 7 7 4 1 Replace the window frame gasket and cabinet window opening gasket at the first sign of media leakage around the view window or if gaskets appear damaged Check the gaskets when changing the view window 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 7 4 2 Remove the window and window frame per Section 7 5 a L 5 16 x 3 4 Gasket Cabinet Front Window Frame 7 5 32 x 3 4 Gasket Q 5 Figure 7 7 4 3 Remove all the old gasket material and clean the surfaces of the cabinet and window frame 7 4 4 Peel a short section of adhesive backing from the 5 16 thick strip gasket and adhere the gasket to the center of the top edge of the window opening as shown in Figure 7 Peel additional backing as needed and work the strip around the radius of each corner
6. Support Table Figure 3 NOTE The track may be placed on either side of the cabinet allowing entry through either door When installing the inside track place it so the stops are opposite the entry door 3 4 2 Place the inside track in the cabinet over the existing grate as shown in Figure 4 Figure 4 3 4 3 Position the track support table and extension as shown in Figure 5 When the hinged extension is lowered the extension tracks must rest on the angled locating supports welded to the bottom of the inside tracks and butt against the inside tracks 3 4 4 Holes are provided on the track table leg pads to permit anchoring when needed 3 4 5 Raise the track extension to allow opening and closing of the door 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS The Hinged Extension must rest on the inside track support angles 4 LZ _7 Extension when lowered P lt Support Angles Figure 5 4 0 OPERATION 4 1 Season Filter Cartridge CAUTION Do not pulse new dust collectors and cartridges until the cartridge is seasoned See Section 7 8 Premature pulsing decreases the efficiency of collector and cartridge life 4 2 Media Loading and Unloading 4 2 1 Media Capacity Media capacity of the Pulsar pressure cabinet is approximately 1 cu ft The machine is full when media reaches the level of the pop up valve Overfilling will
7. and health risk vary with type of media and dust generated by blasting The respirator must be approved for the type of dust generated Identify all material being removed by blasting and obtain a material safety data sheet for the blast media 7 7 1 Close the air supply valve and bleed all air from the pulse manifold 7 7 2 Unlatch and remove the dust collector hopper bottom 7 7 3 Remove the cartridge retaining nut washer and gasket 7 7 4 Slide the cartridge straight down until it clears the holding bar A small amount of rocking may be necessary to break the gasket seal of the cartridge Cartridge Sealing Gasket Filter Cartridge Retaining Nut is Hopper Bottom Z lt _ Hopper Gasket access door y Dust Container C Figure 11 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 7 7 5 Clean all parts that will be reused especially around the cartridge sealing area Scrape off any residual gasket material from the sealing surface 7 7 6 Install the new cartridge and gasket Tighten the retaining nut until the cartridge cannot be moved by hand Tighten the nut one additional full turn 7 7 7 Check the collector hopper gasket for any condition that will prevent the gasket from sealing Replace the gasket if necessary 7 7 8 Attach the hopper bottom and latch in place 7 7 9 Season cartridge per Section 7 8
8. exhaust from the muffler when the foot pedal is released If air does not exhaust remove the muffler and try again If air exhausts now the muffler is blocked If air still does not exhaust the 4 way valve may be faulty 8 2 6 Check the 4 way valve as follows Depressurize the air supply line Remove the tubing leading to either the media metering valve or diaphragm outlet valve Pressurize the air supply line Air should not exhaust from the tube adaptors Press the foot pedal air should exhaust at the tube adaptor Release the foot pedal air should stop exhausting from the tube adaptors If it operates accordingly the metering valve requires service If it does not operate accordingly replace the 4 way valve 8 3 Heavy Media Flow 8 3 1 Make sure the choke valve is open 8 3 2 Media metering valve open too far Adjust per Section 5 2 If adjusting the media valve does not regulate media flow empty the machine depressurize the machine and inspect the internal parts of the valve for wear 8 4 Media Surge A small amount of surge is normal at start up 8 4 1 Heavy media flow Adjust media per Section 5 2 8 4 2 Empty all media from the blast machine and depressurize the blast machine Inspect the internal parts of the media metering valve for wear 8 5 Media Bridging 8 5 1 Frequent bridging or blockage in the media metering valve can be caused by damp media Media becomes damp by blasting parts that are slightly oily
9. from moisture in the compressed air line or from absorption 8 5 2 To avoid contaminating media from the work piece all parts put into the cabinet should be clean and dry If parts are oily or greasy degrease and dry them prior to blasting 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 8 5 3 Moist compressed air may be due to a faulty compressor that overheats or pumps oil or moisture into the air line too long an air line permitting moisture to condense on the inside and from high humidity Drain filters and receiver tank regularly If the problem persists it may be necessary to change media more often or install an aftercooler or air dryer 8 5 4 Absorption Some media absorbs moisture from the air especially fine mesh media in high humidity areas Store media in an airtight container when cabinet is not in use 8 5 5 A vibrator mounted either on the blast machine leg or on a bolt on the media metering valve may help prevent bridging of fine mesh media 8 6 Abnormally High Media Consumption 8 6 1 Fill door on reclaimer not in place improper fit or worn gasket Air entering reclaimer at this point will cause media to be carried into the dust collector DO NOT operate system unless fill door is closed 8 6 2 Outlet damper open too far Adjust static pressure per Section 5 3 8 6 3 Media may be too fine or worn out 8 6 4 Usi
10. result in media carryover to the dust collector and possible blockage in the conveying hose 4 2 2 Media Loading With the exhauster off add clean dry media by pouring it into the reclaimer hopper through the reclaimer door Do not pour media directly into the cabinet hopper as overfilling or blockage may occur Refill only after all media has been recovered from the cabinet 4 2 3 Media Unloading To empty the cabinet and blast machine of media reduce pressure to 40 psi Place an empty container such as a bucket on the cabinet grating Remove the nozzle and nozzle washer close the door close the choke valve and press the foot pedal Direct media flow into the container Empty the container when full or before it is too heavy to handle and repeat the process until the machine is empty Clean the nozzle holder threads before reinstalling the nozzle washer and nozzle If complete purging of media Page 7 is required use a vacuum to remove media residue in the cabinet hopper and blast machine head 4 3 Loading and Unloading Parts 4 3 1 Load and unload parts through either door A WARNING Use solid fixturing to hold heavy parts in place Do not remove lift equipment until the part is adequately supported to prevent movement Moving heavy unsupported parts may cause them to shift or topple and cause severe injury This is especially important with the use of turntables and turntables with tracks 4 3 2 Parts mu
11. screws and move the bracket up or down to center the adjusting screw on the over travel stop Bracket Screws Cabinet Door Figure 6 5 5 Pulse Pressure 5 5 1 Adjust pulse pressure using the regulator mounted on the blast machine piping See Figure 1 Begin pulse at 60 psi 5 5 2 As the filter cartridge cakes with dust it may be necessary to pulse between blasting per Section 6 3 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 5 5 3 When pulsing alone does not adequately clean the cartridge increase pulse pressure in 5 psi increments As dust cakes on the cartridge the differential pressure increases Using a gauge to measure the differential pressure is a good way to tell if the cartridge is heavily caked 5 6 Inlet Damper 5 6 1 Once the inlet is initially set per Section 2 5 it seldom requires readjustment The initial setting produces approximately 1 2 to 3 4 of static pressure in the cabinet enclosure Do not confuse cabinet static pressure with reclaimer static pressure as noted in section 5 3 which is controlled by the outlet damper Reclaimer pressure must be set before cabinet pressure In rare circumstances cabinet pressure may need to be slightly higher or lower 5 6 2 A manometer listed in Section 9 1 is the most accurate method of monitoring and adjusting cabinet pressure Following the instructions pack
12. walls from peening and rapid wear For these applications cabinets can be ordered with reduced size flex hose appropriately sized for steel grit and with rubber curtains installed This special requirement may be specified at the time of order or field installed at a later date See Optional Accessories in Section 9 1 Page 4 1 9 5 Sand and Slag Sand should never be used because of the hazards of using media containing free silica Slags are not recommended because they rapidly break down produce excessive concentrations of dust and quickly load the dust collector 1 10 Compressed Air Requirements 1 10 1 The size of the compressor required to operate the cabinet depends on the size of the nozzle and blasting pressure Unless specified otherwise cabinets are supplied with a 3 16 orifice nozzle Refer to the table in Figure 2 to determine cfm requirements The table shows air consumption of nozzles when new It does not show the recommended compressor size As nozzles wear they will consume 70 to 80 more air Consult with a compressor supplier for suggested compressor size based on the air consumption Nozzle Pressure psi 50 60 70 80 size 50 60 70 80 EE i SEE oe EE se 26 30 33 38 O a A A eT Sre a g or as Air Consumption in cfm Figure 2 1 10 2 The air filter at the blast machine inlet removes condensed moisture from compressed air Its use is especially important in areas of high humid
13. workcart replacement 20 diameter ceeeseeeeeeeeeeeeeeeteteeeeees 24205 30 diameter ceeeeeeeeeeeeeeteeeeteteeeees 24086 1 Turntable replacement 20 diameter cceeesceeeeeeeeeseeeeeteeeeeeees 18329 30 diameter c ce eeeeeeeeeeeeeeteeeeteeeeeeeees 21390 2 Bearing 1 1 2 bore ccceceeeeetteeeeeees 11517 3 Protector DEALING eeeceeeeeeeeeeeeeeeeeeees 13479 4 Screw 1 2 NC x 1 1 2 Cap oo eee 03454 5 Lock washer 1 2 ccccccscesssseeeeeeeeaneaeees 03516 6 Nut 1 2 NC hex ssssssssssssssssirsssrrssrnssnens 03511 7 Caster 4 V QrOOVE sssssssssssnsssnnssennssee nn 11594 All other track items are special order Contact distributor for price and availability Figure 14 Description Stock No Conversion kit Includes all accessories to convert pressure feed system to suction system 21666 Conversion kits Sentinel metering valve To convert from fine mesh media to coarse 22848 To convert from coarse mesh media to fine 22849 Noise reduction arm port kit leessen 24885 Lock pins pkg of 25 for twist on couplings 11203 Safety cable 1 2 NOSE ceeecscceeeesteeeeessteeeeesaes 15012 Page 18 ADFASIVE TAD etie nenea nRT veiibedesaeeeieerts 02011 Window cover lens pkg Of 5 nesses 06190 Manometer kit flexible U tube eeeeeeeeeees 12528 HEPA Filter assembly cceceeeeeceeeeeeeeteeeeneeteeeees 22807 Automatic pulse K
14. 1 4 sassssseesesereeesesesesesess 03117 Cap screw 1 4 X 1 oo ceeeeeeeeteeeteeeeeneeees 03053 Cap diaphragm outlet a se 03393 Body diaphragm outlet eee 06135 Bushing 1 1 4 X 1 ooeeeeeeseeeeeeeeeeteeeeeeeeees 01804 Figure 17 Page 20 9 5 Foot Pedal Assembly Figure 18 Item Description Stock No Foot pedal with tubing cseeeseeeeeees 20194 JE Pedal tO sesiis eain demeesicvess 20017 2 Pedal bottom ceccceeseeeeeeeeeeeeeeeteeeeeeeees 19991 3 Air valve 3 way NC blast valve 20026 4 Valve 3 way pulse valve n 12202 5 Drive pin QrOOVED sisirin 20109 6 Cam follower eeeeeeeeeeeeeeeeeeeeeeeeeeeeseeeeenees 19576 7 Screw socket head 1 4 NF x 3 4 uw 03086 8 Screw fh 10 32 X 1 2 Losses 19571 9 Fitting tube 10 32 pipe x 1 8 barb 11731 10 Fitting 1 8 NPT elbow x 1 8 barb 11733 11 Spring 1 1 4 OD x 3 1 2 Loe eee 20121 12 SD ACEP nice os serials i estuaries fone a a ii 19258 13 Tubing 1 8 ID twin per foot 12 ft req 19577 14 Roll pin 1 8 rinii 20479 15 Screw 8 32 3 8 self tapping 0 11389 16 Bumper neoprene ceeeeeeeseeeeeneeeeeeees 21522 17 Tie nylon wire e sssssssssssessssrsssssessrrenssessens 12139 18 Bracket valve Mount sssecrrrrrrrrerrrrrernn 22858 g
15. 29 Nut plastic window frame 2 required 23035 30 Light assembly with cover s es 23255 31 Gasket light assembly applied to cabinet per foot 7 feet required s es 00187 32 Regulator 1 8 NPT pilot a se 12715 33 Gauge pressure isinen 01908 34 Plate hopper hose ceeeeeeseeeeteeeeees 21657 35 Muffler 1 exhaust cccceseeeeeeeeeeeeeees 05068 36 Adaptor 1 male NPT x 1 male flare 11720 37 Gasket hopper plate adaptor 0ceee 20247 38 Grommet 1 4 ID neseser 12762 13 14 15 ue 27 Conventional stand up model shown Ergonomic replacement parts are same as shown Figure 15 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 9 3 Item 1 2 3 Item 1 lt O Sl CoN Light Assembly Figure 16 Description Stock No Light assembly with cover 0 0 23255 Light fixture assembly less cover 24740 Reflector IONS siasecdicccericateasieceadensderesivlens 23253 Tube fluorescent 20W nosene 24741 Figure 16 1 Diaphragm Outlet Valve Figure 17 Description Stock No 1 Diaphragm outlet valve complete 03371 Nipple 1 x close eeeeeeeeeeeeeeeeteeeeeeeeees 01701 Diaphragm outlet valve n e 06149 Lock washer
16. Description Stock No Blast machine assembly complete 21658 Ball valve 1 with handle choke valve 02396 Handle 1 ball valve ou ceeeeeeeseeereeeees 22531 Regulator with gauge 1 4 essers 12050 Adaptor 1 8 NPT x 1 8 barb 11732 Adaptor 1 male NPT x 1 male flare 11720 Valve 4 Way air 2 ccccccceeeeeeeceeeeeeeeeeeeeeees 12203 CF coupling 1 1 4 seeen 00551 Metering valve Sentinel for 50 mesh and finer media standard 21439 for 50 mesh and coarser media 20608 Inspection door assembly 6 x 8 02377 Gasket 6 x 8 inspection door 02369 Pop up valve 4 ooo eeeeeeeeeeeeeeteeeeeeeeeeeeaees 03699 Guide pop up 1 1 4 x 5 toe nipple 01752 Seat pop up valve nsee 02325 Outlet valve 1 diaphragm 03371 D Page 22 Regulator 1 pilot operated with gauge 12052 Gauge 1 4 COM eeceeeeesteeceeessteeeeeeaaes 11830 Filter 1 AUTO ALAIN cee eeeeeeeeeeeeeeeees 22425 Check valve 1 SWING ccsceceesseeeeeeenees 12187 Muffler 1 4 DrONZE ececcececeeeeeseeeeeeees 03988 Coupling 1 2 blast hose CQA 1 2 00599 Gasket coupling CQG pkg of 10 00850 Nozzle holder CHE 1 2 ccccccccceeeees 00577 Blast hose 1 2 x 25 ft Cut in half to make 2 lengths 04261 Nozzle tungsten carbide CT 2 1 8 OFFICE oo eee urnan 01351 CT 3 3 16 orifice standard
17. ING Failure to wear approved respirators and eye protection when servicing dust laden areas of the cabinet and dust collector and when emptying the dust bag or collector could result in serious eye irritation and lung disease or death Toxicity and health risk vary with type of media and dust generated by blasting Identify all material being removed by blasting and obtain a material safety data sheet for the blast media 7 1 Gloves 7 1 1 Special static dissipating gloves have been provided for operator comfort It will be necessary to Page 11 change gloves periodically as they wear The first sign of deterioration may be excessive static shocks 7 1 2 Gloves are held in place by metal bands on the inside of the cabinet To replace loosen the bands with a screwdriver replace the gloves and tighten the bands 7 2 Nozzle 7 2 1 Replace the nozzle when its diameter has increased by 1 16 or sooner if pressure diminishes noticeably Make sure the nozzle gasket is in place before screwing nozzle into the nozzle holder 7 3 View Window Replacement A WARNING Do not use plate glass for replacement view windows Plate glass shatters on impact and could cause severe injury Use only genuine replacement parts 7 3 1 Remove the two window frame nuts located on the upper edge of the window frame and swing the window frame open Note If the frame is to remain open for cleaning or other reasons remove it per Section 7
18. NING Welding grinding or drilling on the blast machine could weaken the vessel Compressed air pressure could cause a weakened vessel to rupture resulting in death or serious injury Welding grinding or drilling on the blast machine vessel without a National Board R stamp voids the ASME and National Board certification 1 5 2 All welding repairs done on the vessel must be performed by certified welders at shops holding a National Board R Stamp Welding performed by any welder not properly qualified per the ASME Code voids ASME and National Board certification of the vessel 1 5 3 The vessel is rated for a maximum of 125 psi pounds per square inch do not exceed the rated pressure A WARNING Excessive air pressure could cause the blast machine to rupture To prevent serious injury or death do not exceed the rated pressure of the blast machine vessel 1 5 4 OSHA does not require pressure relief valves on blast machines when air compressors supplying air to the blast machines are built to ASME specifications and comply with OSHA regulations ASME Manual section VIII Division 1 UG 125 paragraph A90 g Page 3 states that pressure relief valves or protective devices need not be installed directly on a pressure vessel when the source of pressure is external to the vessel and is under such positive control that the pressure in the vessel cannot exceed the maximum allowable working pressure at the
19. Pulsar IIl P E amp VI P E Series Pressure Cabinets Clemco Industries Corp One Cable Car Drive e Washington MO 63090 Phone 636 239 4300 e Fax 800 726 7559 Email info clemcoindustries com www clemcoindustries com NOTICE TO PURCHASERS AND USERS OF OUR PRODUCTS AND THIS INFORMATIONAL MATERIAL The products described in this material and the information relating to those products is intended for knowledgeable experienced users of abrasive blasting equipment No representation is intended or made as to the suitability of the products described herein for any particular purpose of application No representations are intended or made as to the efficiency production rate or the useful life of the products described herein Any estimate regarding production rates or production finishes are the responsibility of the user and must be derived solely from the user s experience and expertise and must not be based on information in this material The products described in this material may be combined by the user in a variety of ways for purposes determined solely by the user No representations are intended or made as to the suitability or engineering balance of the combination of products determined by the user in his selection nor as to the compliance with regulations or standard practice of such combinations of components or products It is the responsibility of the knowledgeable experienced users of the products mentione
20. a new gasket on the inspection door and bolt the door back onto the machine 7 10 Pop up Valve Seat Replacement 7 10 1 The easiest method to replace the seat is through the reclaimer door If for some reason replacement cannot be made through the reclaimer observe the warning in Section 7 9 and empty the machine and bleed the air supply line Remove the blast machine inspection door and work through the opening 7 10 2 Remove the old seat by using a finger screwdriver or similar object 7 10 3 Push the new rubber seat all the way through the port and then fit it into the groove For the last few inches push on the seat and allow it to pop into position 7 11 Reclaimer Wear Plate Installation 7 11 1 Remove the reclaimer from cabinet 7 11 2 Remove the reclaimer inlet adaptor and old wear plate The wear plate is held in place by screws attached from the outside of the reclaimer Angle the new wear plate into the reclaimer inlet until it is in position with the straight end at the reclaimer inlet Using a board or similar object for leverage pry the wear plate against the inner wall of the reclaimer and install sheet metal screws to hold in place Caulk gaps 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS or voids around the wear plate to prevent rapid wear in those areas 7 12 Sentinel Metering Valve 7 12 1 A separate manual is prov
21. ce the media size and nozzle size that may be used 1 9 2 Glass Bead Glass bead No 10 and coarser may be used with the Pulsar Most beads are treated to ensure free flow operation even under moderately high humidity conditions Glass beads subjected to excessive moisture may be reused after thorough drying and breaking up of the lumps 1 9 3 Silicon Carbide Aluminum Oxide and Garnet These are the most aggressive high volume abrasive in the blasting industry Aggressive media such as these may be used but the service life will be reduced on any equipment components which come in contact with the abrasive To avoid unscheduled down time periodically inspect the reclaimer wear plate hoses and nozzle for abrasive wear When using aggressive abrasive use the optional aluminum oxide kit Interior rubber curtains on the cabinet is suggested Nozzles lined with boron carbide are recommended to extend nozzle wear life See Optional Accessories in Section 9 1 1 9 4 Steel Steel grit and shot may be used but is limited in mesh size and nozzle size The conveying hose on cabinets using steel should be lined and reduced one diameter size from standard Steel grit 80 mesh and finer and S110 and finer shot may be used with a 1 4 or smaller nozzle Under ideal conditions 5 16 nozzles may be used with 120 mesh and finer steel grit See the notation in Section 1 6 regarding 5 16 nozzles Rubber curtains should be used to protect the cabinet
22. cessories is Section 9 1 1 7 HEPA Filters 1 7 1 Optional HEPA after filters provide additional filtration and must be used when removing lead coatings or any other toxic materials See Section 9 1 A WARNING Prolonged exposure to any dust could result in serious lung disease and death Short term ingestion of toxic materials such as lead dust or dust from other heavy metals and corrosives could cause serious respiratory injury or death Identify all materials that are to be removed by blasting Use HEPA after filters if lead coating or any other toxic materials are being removed by the blasting process 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 1 8 Metering Valve Options 1 8 1 Unless specified at the time of order cabinets are shipped with a fine mesh Sentinel metering valve The valve is for use with 50 mesh and finer media and 10 and finer glass bead The optional Sentinel metering valve is for use with 50 mesh and coarser media Conversion kits easily convert the valves either way Kits are listed under Optional Accessories in Section 9 1 1 9 Media 1 9 1 Pulsar pressure cabinets are designed to utilize most common media 180 mesh and coarser that is specifically intended for abrasive blasting The usable media size and nozzle orifice size are based on typical media flow Rich media flow or low static pressure will redu
23. d e g Door Interlock ie Valve a Door Interlock I Actuator On Off Switch Front view of Model VI PE ergonomic cabinet Blast Nozzle Blow off nozzle Pulsar Model VI P shown Model IIl P is identical except for size of cabinet enclosure Figure 1 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 1 4 2 The dust collector filter cartridge is cleaned by a pulse of high velocity compressed air expanding against the inner surface of the cartridge each time the foot pedal is pressed or released The expanding air momentarily reverses airflow through the cartridge to release dust accumulated on the outer surface The dust particles fall away from the cartridges and into the hopper for removal An optional automatic pulse kit can be added to pulse the cartridge at timed intervals during blasting See Optional Accessories in Section 9 1 1 5 Blast Machine and Remote Control 1 5 1 The blast machine pressure vessel is manufactured to American Society of Mechanical Engineers ASME standards as described in Section VII Div 1 and carry a National Board certification It is the owner s responsibility to maintain the integrity of the vessel as may be required by some states This may include regular inspection and hydrostatic testing as described in National Board Inspection Code and Jurisdictional Regulations and or Laws A WAR
24. d in this material to familiarize themselves with the appropriate laws regulations and safe practices that apply to these products equipment that is connected to these products and materials that may be used with these products It is the responsibility of the user to insure that proper training of operators has been performed and a safe work environment is provided Our company is proud to provide a variety of products to the abrasive blasting industry and we have confidence that the professionals in our industry will utilize their knowledge and expertise in the safe efficient use of these products OWNER S MANUAL 2007 Clemco Industries Corp e Stock No 21527 e Manual No 1172 0799 e Date of Issue May 1995 Rev G 11 07 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 1 0 INTRODUCTION 1 1 Scope of Manual 1 1 1 These instructions cover the set up operation maintenance troubleshooting and replacement parts for the following pressure blast cabinets e Pulsar III P Conventional stand up model e Pulsar III PE Ergonomic sit down model e Pulsar VI P Conventional stand up mode e Pulsar VI PE Ergonomic sit down model A separate manual covers the Sentinel abrasive metering valve 1 1 2 These instructions also contain important information required for safe operation of the cabinet Before using this equipment all personnel associated with the blast cabinet operation must read this entire
25. ed with the manometer start the exhauster and insert the needle into a glove and adjust pressure using the inlet damper Open the damper further to decrease static pressure or close it further to decrease pressure 5 6 3 If a manometer is not available use the gloves as an indicator With the exhauster on the gloves should be inflated but not elevated off the grate 5 7 Foot Shelf Ergonomic models only 5 7 1 Raise the shelf to remove pressure from the locating pins and remove the pins Adjust the shelf height and insert the pins 6 0 PREVENTIVE MAINTENANCE WARNING Failure to wear approved respirators and eye protection when servicing dust laden areas of the cabinet and dust collector and when emptying the container could result in serious eye irritation and lung disease Toxicity and health risk vary with type of media and dust generated by blasting The respirator must be approved for the type of dust generated Identify all material being removed by blasting and obtain a material safety data sheet for the blast media Page 10 NOTE To avoid unscheduled downtime establish a weekly inspection schedule Inspect all parts subjected to media contact including nozzle media hose flex hose wear plate and all items covered in this section 6 1 Dust Collector Dust Container 6 1 1 Empty the dust container regularly Start by checking the container at least daily or when adding media then adjust frequency ba
26. eesteeeeesaaes 13116 22 Hose 1 2 ID air specify ft required 12472 23 Regulator 1 8 NPT pilot csse 12715 24 Gauge pressure ssssesssessiessiressrrserreernees 11831 25 Adaptor 1 8 NPT elbow x 1 8 barb 11733 26 Tee 1 4 Drass aariad ratapa iak 02025 27 Foot pedal with tubing n se 20194 28 Metering valve Sentinel for 50 mesh and finer media standard 21439 for 50 mesh and coarser media 20608 29 Regulator 1 pilot operated w gauge 12052 30 Nipple 1 8 NPT hex eeceeeteeteeees 01962 31 Actuator air pilot ccecseseeeeesseeeeeeees 19123 32 Valve diaphragm pulse eeee 19578 1 t 4 3 2 inlet yo 2 outlet Y ee N 2 outle af D 2 inlet Unregulated air Auxiliary air port Plugged use for pneumatic accessories 28 Dr oe ZN g 2 11 a CRE L To OUT Port To IN Port To IN Port lt n i _ amp To OUT Port Pedal shown without top for clarity Figure 19 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 9 7 ltem 1 lt NO OT AON Blast Machine Figure 20
27. en more often if the parts blasted cause excessive debris Always replace the screen after cleaning 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 6 5 View Window Cover Lens 6 5 1 Rapid frosting of the view window can be avoided by directing ricocheting media away from the window and by installing a cover lens on the inside surface of the window Using cover lenses prolongs the life of the view widow 6 5 2 The best way to install a cover lens is to remove the window from the cabinet If for some reason it is not helpful to remove the window the lens may be applied with it in place 6 5 3 To install a cover lens remove the adhesive backing and apply the lens to the clean dry inner surface of the view window When the cover lens becomes pitted or frosted replace it 6 6 Air Filter 6 6 1 The cabinet is equipped with an auto drain air filter The filter automatically drains when moisture fills the bowl to a certain level Moist air inhibits the flow of media Drain the air line and receiver tank regularly If the moisture problem persists it may be necessary to install an aftercooler or air dryer 6 7 Blast Hose and Couplings 6 7 1 To avoid unscheduled down time inspect the blast hose for thin spots by pinching it every 6 to 12 inches Check coupling gaskets and couplings for leaks and wear 7 0 SERVICE MAINTENANCE A WARN
28. equired 1X9 al P aa cere eeercrree es 14244 TOP VP eia aneta tevin gota bined dete cbeteselentate a aiaia an 14245 Rubber sump liner set black for II P TOP WEP Actes seed piced a e tec cntdey ts 23499 Steel media applications order the following as required 4 universal cabinet hopper adaptor 23295 Gasket hopper outlet adaptor ccceseeeeee 23258 4 reclaimer inlet adaptor cceceeeeseeeeees 12350 Gasket inlet adaptor 2 ceecceeesteeeeeesteeeeeees 11779 A light lined hose eceeeeeeeeeeeeeeeeeeeteeteeeneees 12466 Ill requires 6 feet VI requires 7 feet Rubber curtains accenn as shown above 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR IIl P III PE and VI P VI PE PRESSURE CABINETS 9 2 Item 11 12 Cabinet Assembly Figure 15 Description Gasket door per ft specify feet req d Pulsar Ill requires 11 feet Pulsar VI requires 13 feet Left door assembly for Pulsar Il srair eee for Pulsar VI eatae tak arii Right door assembly for Pulsar Il oo eee for Pulsar VI oo e cee iani Grate for Pulsar Marearea for Pulsar VI cccccescecesssteeeeessteeeeees Window cover lens pkg of 5 aeee Window glass 12 5 x 19 5 oe Gasket 5 16 x 3 4 applied to cabinet per foot 6 feet required s Gasket 5 32 x 3 4 applied to frame per foot 6 feet required Latch kit door steini Adaptor pipe 5 un
29. er attempt to override the interlock system Doing so could result in injury from unexpected blasting 5 4 1 The door interlocks disable the blasting control circuit when the doors are open To enable blasting the Page 9 door interlock switch must be engaged when the doors are closed The interlocks are set at the factory and do not usually require field adjustment unless parts are replaced When adjustment is required proceed as follows 5 4 2 Close cabinet doors 5 4 3 Loosen the actuator bracket screws and adjusting screw nut Move the actuator adjusting bracket up or down and the adjusting screw sideways to center the adjusting screw on the over travel stop Tighten the bracket screws 5 4 4 Turn the adjusting screw in or out as required to engage the switch without applying excessive pressure on it Tighten the adjusting screw nuts 5 4 5 Test the operation with the doors open and then again closed The interlocks should prevent blasting when the doors are open and permit blasting when the doors are closed NOTE Negative pressure inside the cabinet may cause the doors to flex inward Tests should be performed with the exhauster on Over travel Stop Adjusting Screw Nut Loosen and move sideways to center the adjusting screw on Detent Sleeve the over travel stop Adjusting Screw ia Adjust the screw to depress the ak valve stem when door is closed Actuator Adjusting Bracket Loosen the bracket
30. essory A WARNING Do not look into the reclaimer exhauster outlet while the paddle wheel is turning Injury to the eye or face could occur from objects being ejected from the exhauster 2 4 3 Check the rotation of the motor To check jog the starter momentarily turn switch on and off This will cause the motor to rotate slowly Look through the slots in the fan housing on top of the motor where rotation of the fan can easily be observed Proper rotation is indicated by the arrow on the exhauster housing The fan should be rotating clockwise when viewed from the fan end of the motor 2 5 Inlet Damper 2 5 1 The inlet damper must be set to match the cabinet dimensions and reclaimer size The decal on the damper show the settings in degrees For the initial setting align the handle to 0 degree full open See Section 5 6 for adjustment procedure 2 5 2 Loosen the lock nuts and set the damper to the starting point When correctly positioned tighten the lock nuts to maintain the setting 2 6 Final Assembly 2 6 1 Position the foot pedal on the floor at the front of the cabinet or on the foot shelf on ergonomic models 2 6 2 A package of 5 cover lenses is supplied with the cabinet To install a cover lens remove the adhesive backing and apply the lens to the clean dry inner surface of the view window per Section 6 5 When the cover lens becomes pitted or frosted replace it 3 0 FIELD INSTALLED ACCESSORIES 3 1 Alox aggress
31. ff the cabinet as shown in Figure 9 7 6 2 2 Remove all the old gasket material and clean the surfaces of the cabinet 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS Handle Light Assembly F ra Jf Wing nut ZA l Gasket A mae Figure 9 7 6 2 3 Lay a section of strip gasket next to the opening and cut to length allowing 3 4 overlap on each end Peel a short section of adhesive backing and adhere the strip gasket to the top edge of the light opening as shown in Figure 9 Press the gasket tightly to bond Repeat the process for each side compressing the ends to seal 7 6 3 Lens and Tube Replacement 7 6 3 1 Remove the four holding wing nuts and use the handles to lift the fixture off the cabinet 7 6 3 2 Flip the assembly over to access the lens screws ref Figure 10 7 6 3 3 Remove the four lens screws and remove the lens Lens Screws 4 Lens in Figure 10 7 6 3 4 Replace the lens or tubes as required Page 13 7 6 3 5 Inspect the gasket and replace if worn or damaged 7 6 3 6 Reassemble in reverse order 7 7 Filter Cartridge Replacement Figure 11 4 WARNING Failure to wear approved respirators and eye protection when servicing dust laden areas of the cabinet and dust collector and when changing the filter cartridge could result in serious eye irritation and lung disease or death Toxicity
32. ided for the metering valve Refer to the metering valve manual for servicing and replacements parts 8 0 TROUBLESHOOTING A WARNING To avoid serious injury observe the following when troubleshooting Turn off the air and lockout and tagout the air supply e If checking the controls requires air always enlist the aid of another person to Hold the nozzle securely Operate the foot pedal Never bypass the foot pedal or wedge it in the operating position Never override the door interlock system 8 1 Neither Media Nor Air Comes Out The Nozzle When The Foot Pedal Is Pressed 8 1 1 Depressurize the blast machine and check the nozzle to see if it is plugged 8 1 2 Make sure the blast machine pressurizes when the foot pedal is pressed If it does not see Section 8 8 8 1 3 Make sure the media metering valve and the choke valve are open 8 2 Air Only no media Comes Out The Nozzle 8 2 1 Make sure the machine contains media 8 2 2 Verify that the metering valve is not closed 8 2 3 Make sure the blast machine is pressurized See Section 8 8 8 2 4 Check for minor blockage in the media metering valve by fully opening the metering valve and closing the choke valve Activate the foot pedal to blow out obstructions If this procedure fails depressurize the Page 15 machine open the metering valve clean out cap and check for foreign objects 8 2 5 Check the muffler on the 4 way air valve Air should
33. isconnection while under pressure Hose disconnection while under pressure could cause serious injury 2 3 Ground Cabinet 2 3 1 To prevent static electricity build up attach an external grounded wire from an earth ground to the grounding lug on the left rear of the power module 2 4 Connect Electrical Service A WARNING Shorting electrical components could result in serious electrical shocks or equipment damage All electrical work must be performed by a qualified electrician and comply with applicable codes NOTE 115 volt 1 phase wiring schematics are packaged with this manual 3 phase schematics are packed in the control panel After wiring is completed keep the schematic with the manual for future reference and for electrical replacement parts 2 4 1 If voltage is 115 volt 1 phase a power cord is supplied No additional wiring is required REFER TO THE FOLLOWING IMPORTANT WARNING A WARNING Do not use electrical adaptors that eliminate the ground prong on 115 volt plugs Doing so can cause electric shock and equipment damage 2 4 2 If voltage is optional 230 volt 3 phase a magnetic starter is located in the control panel User supplied wiring will need to be run from a disconnect to the control box assembly As much wiring as possible Page 5 has been completed at the factory The user needs only to provide power to the motor starter mounted in the panel A wiring diagram is supplied with the acc
34. it 0 0 0 eeeeseeeeeeneeeeeeeneeeeeeaaes 21773 Time delay door release for both doors 24163 Differential pressure gauge assemblies for reclaimer static pressure s 23355 for dust collector drop across cartridge 23356 Boron carbide nozzle CTB 2 1 8 orifice oo eect eeeeececeeeeeeeeeeeteeeeeeeetees 21090 CTB 3 3 16 orifice ooo eee eect eset eteteeeeeeeeeeee 21091 CTB 4 1 4 orifice oo eee eeeececeeeeeeeteeeeneeeeeeeeeees 21092 Aluminum oxide and aggressive media applications order the following CTB 3 3 16 orifice boron carbide nozzle 21091 Set Of curtains 0 0 ee eeren as shown below Rubber curtain set black for III P Conventional cccceeeeesseeeeeseeeeees 23531 for III PE ergonomic eeeeeeeeeeeeeteeeeeteeeeees 25086 for VI P Conventional cccccseesseeeeeteeeeeees 23532 for VI PE ergonomic eeeeeeeteeeeteeeeeeeeeees 25087 Rubber curtain set white for III P Conventional ccceseeeeseeeeeneeeeeees 23541 for III PE ergonomic ceeeeeeeeeeeeseeeeeneeeeees 25088 for VI P Conventional ccceceeeeseeeeeteeeeeees 23542 for VI PE ergonomic ceeeeeeeeeeeeteeeeeeeeeees 25089 Rubber curtains black Individual for conventional models Back curtain 0 Fl oeeerreeeeee cer E AE 14243 TOF A A E E E AE E EE 14247 Front curtain TOP WEP A E E EEA AEE 14242 OTA E EE EAE E 14246 Door curtain 2 r
35. ity or when fine mesh media are used Moisture causes media to clot and inhibits free flow through the feed assembly If moisture problems persist an air dryer may be required 1 11 Electrical Requirements 1 11 1 Electrical requirements depend on the size and phase of the motor Standard cabinets are supplied with 1 HP 115 230V 1 PH 60 HZ wired 115 1 11 2 If voltage is 115 1 phase a power cord is supplied If voltage is optional 230 460 3 phase there will be a magnetic starter mounted in a control box Power from the user s disconnect has to be wired to it Additional wiring information is in Section 2 4 2 0 INSTALLATION 2 1 General 2 1 1 Select a location where compressed air and electrical service are available The cabinet location 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS must comply with OSHA and local safety codes Allow for full access to all doors and service areas and for efficient handling of large parts 2 2 Connect Compressed Air Supply Line 2 2 1 Install an isolation valve at the compressed air source to enable depressurization for service Connect a 1 ID or larger air line from the air source to the air filter inlet A smaller diameter hose may reduce blasting efficiency A WARNING If twist on type air hose couplings are used they must be secured by safety lock pins or wires to prevent accidental d
36. ive media Kit 3 1 1 The optional aluminum oxide kit is available factory installed or may be field installed later The factory installed Alox kit consists of four rubber curtains with eyelets curtain hardware and boron carbide nozzle Refer to Section 3 2 for curtain installation Field installed kits also include light lined flex hose and reclaimer wear plate 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS NOTE Wear plates and lined flex hose are standard on current cabinets If the cabinet has both items and they are in good condition reserve the new wear plate and hose for future replacement 3 2 Curtain Installation 3 2 1 Match curtains to corresponding walls and door 3 2 2 Front and rear walls Position the curtain on the wall to be protected Using the curtains as templates mark each mounting point through the grommet holes along the upper edge of the curtain NOTE When laying out the attachment points the upper edge of the rear curtain should be below the bottom edge of the air duct partition Remove the curtains and drill a 187 3 16 diameter hole at each point marked Install the curtains using the fasteners provided machine screw 11 16 OD flat washer lock washer and nut at each grommet The flat washer is used between the screw head and the rubber curtain grommet on all curtains 3 2 3 Doors Using protectors agains
37. iversal flex Standard 4 for Pulsar IIl w steel media 4 for Pulsar VI w steel media Gasket flex hose adaptor pipe A for Pulsar Wl woo eee 5 for Pulsar Vl ww eee sees ee eee Grommet blow off hose 0 c ee Stock No 00187 Page 19 13 GIOVE SEI geste eats lee EA Bie eas ints 11215 14 Glove left only ceecesessceeeesssseeeeseeeeees 12710 15 Glove right only siseses 12711 16 Clamp glove eeeeeeeeeeeeeeeseteeeseeeeeeeeeeeeees 11576 17 Motor exhauster 1 hp 115 volt 1 ph standard eee 12314 230 460 3 ph Special c ees 12310 18 Paddle wheel Pulsar VI P ssec 19234 19 Plate MOOK ccccccessscecsesseeeessseeeeessssseeeeeses 20224 20 Air valve 3 way door interlock 4 12202 21 Over travel stop door interlock 20004 22 Detent sleeve door interlock 066 15042 23 Actuator adj door interlock e 19152 24 Grommet blast hose ccceeeeeeeeeeees 00184 25 Clamp 5 flex hose ooo eeeeeeseeesteeeeeeeeees 11578 26 Switch toggle ccceeeceeeseeesseeeesseeeeeees 12127 27 Hose light lined flex 4 for steel media 7 ft req d e 12466 5 for standard use 7 ft required 12467 28 Foot pedal with tubing ceeeeeeee 20194
38. manual and all accessory manuals to become familiar with the operation parts and terminology 1 2 Safety Alerts 1 2 1 Clemco uses safety alert signal words based on ANSI Z535 4 1998 to alert the user of a potentially hazardous situation that may be encountered while operating this equipment ANSI s definitions of the signal words are as follows This is the safety alert symbol It is used to alert the user of this equipment of potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A CAUTION Caution used without the safety alert symbol indicates a potentially hazardous situation which if not avoided may result in property damage CAUTION Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Page 1 A WARNING Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury A DANGER Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury 1 3 General Description 1 3 1 Pulsar pressure cabinet encloses the blasting environment to provide efficient blasting while maintaining a clean surrounding work area Production rates are influenced by size of nozzle compressor output working pressure type and size of media and angle and distance of the nozzle from the blast s
39. ng friable media that rapidly breaks down 8 6 5 Nozzle pressure too high for media causing media to break down 8 6 6 Hole worn in reclaimer or leak in reclaimer seams Check entire reclaimer for negative pressure leaks 8 7 Plugged Nozzle 8 7 1 A damaged or missing reclaimer screen will allow large particles to pass and block the nozzle Replace or re install as necessary 8 8 Blast Machine Will Not Pressurize 8 8 1 Make sure the compressor is on and air supply valve is open 8 8 2 Make sure the pressure regulator is not set too low minimum pressure is 40 psi 8 8 3 Door interlocks not engaging Check adjustment per Section 5 4 Page 16 8 8 4 Inspect the diaphragm in outlet valve for wear 8 8 5 Check pop up valve and seat for wear and misalignment 8 8 6 Blocked or leaking control lines Check all urethane tubing for blockage or leaks 8 8 7 Foot pedal valve malfunction Check foot pedal alignment and inlet and outlet lines for pressure 8 8 8 Make sure lines are not reversed on the foot pedal or pilot regulator See schematic in Figure 20 8 8 9 Check the 4 way valve for jamming per Sections 8 2 5 and 8 2 6 When the foot pedal is pressed the valve should shift pressurizing the line to the outlet valve and media metering valve 8 8 10 Inspect the check valve for obstruction or broken flap 8 9 Blast Machine Will Not Depressurize Or Depressurizes Too Slowly 8 9 1 Check for blockage in the 4 way
40. operating temperature OSHA regulation 1910 169 refers to the above ASME code when describing the necessity of pressure relief valves on compressed air equipment DO NOT operate blast machines with air compressors that are not equipped with properly functioning pressure relief valves American Society of Mechanical Engineers Boiler and Pressure Vessel Code 1989 Occupational Safety and Health Administration 29 CFR 1910 Subpart M Compressed Gas and Compressed Air Equipment 1 5 5 When the air supply is on and the cabinet doors are closed the blast machine is ready for actuation by the foot pedal Pressing the foot pedal opens the normally closed main inlet regulator and closes the normally open outlet valve The incoming air pressurizes the blast machine and blasting begins When pressure on the foot pedal is released the blast machine depressurizes and blasting stops 1 6 Nozzle Options 1 6 1 Unless otherwise specified at the time of order cabinets are shipped with a 3 16 orifice tungsten carbide nozzle Optional 1 8 1 4 and 5 16 orifice nozzles are also available 5 16 nozzles should be used only when necessary in applications that require a high volume of air When using 5 16 nozzles media flow should be lean or recovery from the cabinet hopper may be impaired 5 16 orifice nozzles will substantially increase wear on blast hose Use boron carbide nozzles when blasting with aggressive media See Optional Ac
41. sed on usage contamination and friability of the media 6 1 2 Turn off the exhauster and release the dust container from the cover The cover s flexible inlet hose allows easy removal Remove the container and dump the contents into a suitable disposal container Replace the container being certain the cover is in place NOTE Blasting media is usually non toxic however some materials being removed by the process may be toxic Check with proper authorities for disposal restrictions 6 2 Pulse Manifold 6 2 1 Open the petcock to drain water from the pulse manifold before and after each use Refer to Figure 11 for the location of the drain petcock 6 3 Cartridge Pulsing 6 3 1 The cartridge is pulsed each time the foot pedal is pressed or released Additional pulsing should be performed per the following instructions every eight hours or more often under dusty conditions to prevent clogging of the cartridge 6 3 2 Turn off exhauster 6 3 3 Hold the blast nozzle and rapidly press and release the foot pedal three times Activating the pedal more than three times may cause dust to escape from the enclosure 6 3 4 Start the exhauster and let it run until all airborne dust is cleared from the cabinet 6 3 5 Repeat the process once or twice 6 4 Reclaimer Debris Screen 6 4 1 The screen is accessible through the reclaimer door With the exhauster off remove the screen and empty it daily or when loading abrasive Empty the scre
42. st be free of oil water grease or other contaminants that will cause media to clump or clog filters 4 3 3 When blasting very small parts place an appropriately sized screen over the work table to prevent parts from falling into the hopper 4 3 4 Close door Be certain door is sealed securely or door interlock system will prevent blasting 4 4 Blasting Operation A CAUTION e Always close cabinet reclaimer and dust collector doors before blasting Keep all doors closed during blasting e Always wear blast gloves e Avoid pointing the blast nozzle toward the view window e Use the blow off nozzle to blow media off parts before doors are opened or exhauster is switched off e After blasting keep doors closed and exhauster on until the cabinet is clear of all airborne dust e Stop blasting immediately if dust leaks are detected 4 4 1 Slowly turn on air supply to the cabinet Check for air leaks on the initial start up and periodically thereafter 4 4 2 Adjust the dust collector pulse pressure regulator to 60 psi See Figure 1 for location 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 4 4 3 Turn on lights and exhauster The on off toggle switch performs both functions 4 4 4 Load parts 4 4 5 Close door Be certain door is sealed securely or door interlock system will prevent blasting 4 4 6 Insert hands into glo
43. t pedal pressurizes the blast machine and propels blast media through the blast hose and out the nozzle After striking the object being blasted blast media along with fines dust and by products generated by the blasting process fall through Exhauster Rear view of Model VI P conventional cabinet Pulse Manifold Dust Collector Inlet Dust Collector 115V 1 PH Supply Cord en Dust Collector Hopper yk access door Grounding Lug Dust Container Cover Plate For optional HEPA Filter Inlet Damper Pilot Regulator Blast Pressure NgZ A Exhaust Muffler Adjustable Foot Shelf Ergonomic Models only Foot Pedal Lifting gt Page 2 the perforated worktable into the cabinet hopper These particles are drawn into the reclaimer for separation Dust and fines are first separated from the reusable blast media The media is then screened to capture oversized particles and clean media is held in the reclaimer hopper for reuse When the foot pedal is released the blast machine depressurizes allowing stored media to refill the machine Dust and fines are drawn through the reclaimer into the dust collector which traps the dust discharging clean air Outlet Damper Access from underneath Reclaimer ponm i Screen Blast Machine Blast Hose Blow off Hose Pressure Regulator Dust Collector pulse Air Filter OZ Yaa A
44. t the curtains and outer doors clamp the door curtains in place NOTE When laying out the attachment points the upper edges of the door curtains should be even with the outer edges of the door s sound proofing panel Insert a 10 self drilling screw with an 11 16 OD flat washer through the grommet holes Use a screw gun with a 5 16 socket to drill and thread the screws through the door s inner wall at each grommet 3 3 Differential Pressure Devices 3 3 1 Constant static pressure is necessary for precise media separation as the reclaimer s efficiency is accomplished by a centrifugal balance of air particle weight and size The air balance and static pressure are set by adjusting the outlet damper A flexible u tube manometer or differential pressure gauge measures static pressure Use the instruction sheet provided with the manometer or pressure gauge for installation and operation instructions The optional manometer and differential pressure gauge kits are listed in Section 9 1 3 4 Turntable with Workcart and Track 3 4 1 The components of the Turntable and track assembly are shown in Figure 3 The assembly consists of 1 The inside track assembly which is placed inside the cabinet 2 The hinged track extension which is attached to the table and swings up to clear the door 3 The track support table 4 Turntable and workcart assembly Page 6 Turntable and Workcart Hinged Track Extension Track
45. ted above the reclaimer on the underside of the power module top See Figure 1 If the damper is not opened far enough the reclaimer will not remove fines resulting in dusty media poor visibility or will not convey media causing build up in the hose between the cabinet hopper and reclaimer If the damper is opened too far it may cause carry over usable media carried into the dust collector and result in excessive media consumption Open only as far as necessary to obtain a balance of dust removal without media carryover 5 3 3 A flexible u tube manometer or differential pressure gauge is useful for adjusting and monitoring static pressure The manometer kit and reclaimer differential pressure kit are listed under Accessories and Replacement Parts in Section 9 1 The following are static pressure starting points for given media Static pressure may need to be lower with finer media higher with coarser media Glass Bead No 8 to 10 0 ee eeece cece ee eeee 2 1 2 3 AlOx 60 amp COAMrSED oc ceeececeeecccceeeecesseeeeseeeeessaneeeeseanes 4 5 Alox 80 amp fiIN P oo ceccees seen e i 2 1 2 3 5 3 4 As the cartridge develops a cake of dust the static pressure will drop requiring additional pulsing of the cartridge as described in Section 6 3 or an increase in pulse pressure per Section 5 5 When pulsing no longer maintains the necessary static pressure readjust the damper 5 4 Door Interlocks Figure 6 4 WARNING Nev
46. th media stored in the reclaimer each time the foot pedal is released Refill takes approximately 15 seconds when the machine is empty Page 8 4 5 3 Use the blow off nozzle to blow media off cleaned parts Allow the exhauster to clear the cabinet of airborne dust before opening the door 4 5 4 Unload parts shut off the air supply valve and switch off the lights and exhauster 4 6 Blasting Technique 4 6 1 Blasting technique is similar to spray painting technique Smooth continuous strokes are usually most effective The distance from the part affects size of blast pattern Under normal conditions hold the gun approximately 6 from the surface of the part 4 7 Pulsing Cleaning Dust Collector Cartridge 4 7 1 The dust collector filter cartridge is pulsed each time the foot pedal is pressed or released Prolonged periods of blasting or dusty conditions may require the cartridge to be pulsed during the blasting process per Section 6 3 or upgrade to the automatic pulse kit See Section 9 1 5 0 ADJUSTMENTS 5 1 Blasting Pressure 5 1 1 The blast pressure pilot regulator located on the top left side of the cabinet enables the user to adjust blasting pressure to suit the application The suitable pressure for most purposes is 80 psi Lower pressures may be used for delicate work In all cases highest production can be achieved only when pressure is carefully monitored 5 1 2 Pressure registers on the gauge only while blas
47. ting To adjust pressure unlock the knob and turn it clockwise to increase pressure or counterclockwise to decrease pressure Once operating pressure is set lock the knob to maintain the setting 5 2 Media Metering These instructions are for a standard cabinet with Sentinel Metering Valve Optional metering valves may function differently but the process is similar 5 2 1 Media flow is adjusted by the metering valve located at the bottom of the blast machine The valve is closed when the handle is fully right To adjust begin with the valve closed depress the foot pedal and have someone slowly move the handle to the left to increase media flow Allow time for the flow to stabilize before further adjusting The valve is fully open when the 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR IIl P III PE and VI P VI PE PRESSURE CABINETS handle is at the full left position The optimum flow rate depends on the type and size of media and blasting pressure and can best be determined by experience Use as little media as possible to do the job while maintaining the best cleaning rate Generally with the correct mixture abrasive can be seen as light discoloration as it exits the nozzle 5 3 Static Pressure outlet damper 5 3 1 Static pressure requirements vary with size of reclaimer and size weight and type of media 5 3 2 Adjust static pressure by opening or closing the outlet damper loca
48. uipment until the part is adequately supported to prevent movement Moving or rotating heavy unsupported or off centered parts may cause them to shift or topple and cause severe injury Stationary Turntable without Bearing 25 Ib Capacity Description Stock No 20 diameter 25 Ib Capacity 0 cceeeeeeeeeees 12412 Stationary Turntable with Bearing 500 Ib Capacity Figure 13 Item Description Stock No 20 diameter turntable assembly 12411 30 diameter turntable assembly 14138 1 Turntable replacement 20 diameter ee 18329 30 diameter ccc eeeeeeeeteeeeeeeeeteees 21390 2 Bearing 1 1 2 bore ccceetsceeessteeeees 11517 3 Protector bearing e eeeeeseceeeeeeeeeeeeees 13479 4 Screw 1 2 NC x 1 1 2 cap eeccceeeeeees 03454 5 Lock washer 1 2 cccccccccececeesseeeeeeeeeees 03516 6 Nut 1 2 NC hex ccccccccceseceeesteeeeesseeeeeees 03511 Figure 13 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS Turntable with Workcart and Track 500 Ib Capacity Figure 14 Item Description Stock No 20 diameter turntable and track assembly for Pulsar III models ceeeeeeeees 13530 for Pulsar VI models 0 ceeeeeeeees 12835 30 diameter turntable and track assembly for Pulsar VI models only eccee 24045 Turntable and
49. uired ceee 12452 Gasket adhesive backed 1 8 x 2 5 ft required ooo eee eeeeteeeeeeeeeeteeeeteeteeeees 13089 Figure 21 Page 23 9 9 Dust Collector Figure 22 Item Description Stock No Repair kit diaphragm pulse valve 21600 1 Valve 1 diaphragm pulse c ee 19578 2 Vave S WAY orare a i int aie 12202 3 Fitting 1 8 NPT x 1 8 barb seeen 11732 4 Nipple 1 8 NPT hex nesses 01962 5 Actuator air pilot 0 cceceeeeeteeeeeteeeeees 19123 6 Fitting 1 4 NPT x 3 8 tube 11736 7 PEtCOCK diagoned peia ea eaa ade a 01993 8 Filter cartridge 12 X 30 oo eeeeeeeeeeeee 19121 9 Hopper assembly includes items 10 amp 11 24029 10 Gasket 5 16 x 1 adhesive backed Pulsar VI requires 7 feet ceeee 00187 11 Latch assembly sses 11876 12 Hose 4 flex 1 ft minimum order 12447 13 Clamp 4 hose eceeeeeeeeeeeeeeeeeeeeeeeeeeee 11577 14 Dust container assembly includes items 12 amp 13 wees 23411 15 Washer 1 2 ID x 1 1 16 OD aeee 03515 16 Elbow 1 4 brass St eeeeseseeeeeeeeeeeeees 02027 17 Washer 1 2 100K ccccccccccccceseseeeeeeeenenenees 21699 18 Nut 1 2 NC WING 0eeeseeeeeeeeeeeeeeeneeeees 20108 Figure 22 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527
50. urface See Figure 1 for arrangement of components Pulsar pressure cabinets consist of two major components 1 Cabinet Enclosure 2 Pulsar VI Power Module Note Pulsar IIl P E and VI P E cabinets both include Pulsar VI P Power Modules 1 3 2 Cabinet Enclosure This manual covers two Pulsar cabinet sizes Each is available as a conventional stand up model and ergonomic sit down model totaling four separate models Pulsar Ill P E Approximate work chamber dimensions 36 wide x 35 deep x 37 high Pulsar VI P E Approximate work chamber dimensions 50 wide x 39 deep x 43 high NOTE The offset front on Ergonomic models provides approximately 12 inches additional depth from the arm port and above and is approximately 3 inches narrower than the widths shown above 1 3 3 Power Module Pulsar VI power module is approximate 50 wide x 32 deep The module contains a 600 cfm reverse pulse dust collector and 600 cfm reclaimer mounted above a 1 cubic foot blast machine Pulsar VI pressure blast modules are easily converted to suction systems using the conversion kit listed under Optional Accessories in Section 9 1 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR Ill P III PE and VI P VI PE PRESSURE CABINETS 1 4 Theory of Operation 1 4 1 When the air supply is on and the cabinet doors are closed the blast machine is ready for actuation by the foot pedal Fully depressing the foo
51. utlet and dust collector 8 10 8 Reclaimer fill door open 8 10 9 Obstruction in flex hose between the cabinet hopper and reclaimer inlet 8 11 Static Shocks 8 11 1 Cabinet and or operator not grounded Abrasive blasting generates static electricity The cabinet must be grounded to prevent static buildup See Section 2 3 If shocks persist the operator may be building up static Attach a small ground wire such as a wrist strap from the operator to the cabinet 8 11 2 Avoid holding parts off the grating Static will build in the part if not dissipated through the metal cabinet 8 12 Reduction in Blast Cleaning Rate 8 12 1 Incorrect metering valve adjustment Adjust media flow per Section 5 2 8 12 2 Reduced air pressure caused by a malfunctioning regulator a dirty filter element in the air filter ruptured or leaking air line or demand by other air tools in use 8 12 3 Moist media Frequent bridges or blockage in the area of the metering valve can be caused by moisture See Section 8 5 8 13 Dust Leaking From Dust Collector 8 13 1 Damaged or loose cartridge Inspect cartridge 8 13 2 Faulty seal on the dust collector cone Inspect seal and replace if damaged Page 17 9 0 ACCESSORIES AND REPLACEMENT PARTS 9 1 Optional Accessories Turntables and Turntables with Tracks A WARNING Turntable capacities are based on concentric loading Use solid fixturing to hold heavy parts in place Do not remove lift eq
52. valve mufflers 8 9 2 Check that the foot pedal valve exhausts air when pedal is released If it does not replace the valve 8 9 3 Check the outlet muffler located inside the cabinet for blockage 8 9 4 Check 4 way air valve for jamming per Sections 8 2 5 and 8 2 6 8 9 5 Check for blockage in the screen of the optional abrasive trap 8 10 Poor Visibility 8 10 1 Dirty filter cartridge Empty the dust container Cycle pulse several times Inspect and replace the cartridge if necessary 8 10 2 Motor rotating backwards The motor should rotate as indicated by the arrow on the housing If it does not rotate in the proper direction Lockout and Tagout power and switch the motor leads as shown on the motor plate See Section 2 4 3 8 10 3 Using friable media that rapidly breaks down or using media that is too fine or worn out can cause poor visibility 2007 CLEMCO INDUSTRIES CORP e www clemcoindustries com e Manual No 21527 PULSAR III P III PE and VI P VI PE PRESSURE CABINETS 8 10 4 Outlet damper closed too far restricting air movement in cabinet Adjust static pressure per Section 5 3 8 10 5 Exhauster motor not operating Exhauster must be in operation before blasting begins 8 10 6 Inlet damper requires opening A restriction at the inlet damper reduces air movement in the cabinet Open damper per Sections 2 5 and 5 6 8 10 7 Hole worn in flex hose between cabinet hopper and reclaimer inlet or reclaimer o
53. ves 4 4 7 To blast firmly grasp the nozzle and step on the foot pedal blasting will begin almost immediately NOTE When blasting small parts use a solid back rest for the part Without this assist especially with long blasting operations the operator will tire easily from resisting blast pressure Whenever possible avoid holding small parts that will require blasting into the glove 4 4 8 Adjust the pilot pressure regulator located on the top left side of the cabinet to the required blasting pressure per Section 5 1 4 4 9 When blasting very small parts place an appropriately sized screen over the grate to prevent parts from falling into the hopper If an object should fall through the grate stop blasting immediately and retrieve it WARNING Shut down the cabinet immediately if dust discharges from the collector Check that the filter is correctly seated and not worn or damaged Prolonged breathing of any dust could result in serious lung disease or death Short term ingestion of toxic dust such as lead poses an immediate danger to health Toxicity and health risk vary with type of media and dust generated by blasting Identify all material being removed by blasting and obtain a material safety data sheet for the blast media 4 5 Stop Blasting 4 5 1 To stop blasting remove pressure on the foot pedal The blast machine will depressurize each time the foot pedal is released 4 5 2 The blast machine refills wi
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