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Sponge-Jet B-VAC User Manual

1. 6 6 Feed Unit will not stop running 1 Depress the Emergency Stop Button Fig B 1 on the Control Panel Fig B inset Feed Unit should stop 2 If Feed Unit will not stop close Main Air Ball Valve Fig B 8 and allow the Feed Unit to depressurize fully Open Main Air Ball Valve 3 Ifa continuous leak of air is heard from the Deadman Handle Fig H 6 then reverse the Twinline Quick Connect Fittings Fig A 6 at the Feed Unit end of the Twinline re test according to Section 4 0 and resume blasting 4 If Feed Unit pressurizes without depressing the Deadman Handle contact oponge Jet immediately at 800 776 6435 USA or 603 431 6435 6 7 Deadman Control is exhausting air while in shutdown condition 1 Reverse Twinline Quick Connect Fittings at Feed Unit end of Twinline 2 Ifthe Deadman Handle Fig H 6 is still leaking remove Clean Out Screw Fig 5 depending on model in Deadman Handle Check for debris within the Deadman Handle clean and replace Sponge Jet B VAC User Manual 10 February 2005 Page 20 of 55 Troubleshooting continued 6 8 Auger will not begin rotating 1 First check that the Media Feed Pressure Gauge Fig B 3 registers adequate operating pressure 1 4 bar 10 to 60 psi while the Feed Unit is engaged 2 f necessary increase this pressure by turning the Media Feed Pressure Regulator Handle Fig B 6 in a clockwise direction The pressure level of the Media Feed Pressure Gaug
2. Red Sponge Media 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 B VAC User Manual 10 February 2005 Page 28 of 55 ooo Sponge Jet Feed Unit _ Requirements Continued 7 6 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 lightweight 6 to 10 mil poly containment can contain the abrasive sponge More stringent containment may be required when working with hazardous substances and in areas where dust is a critical concern These types of containment may also require negative air machines to further reduce dust levels inside the containment as well as outside the containment When working with hazardous substances always follow local state and federal guidelines concerning proper containment containment ventilation and monitoring procedures Containment also serves another purpose it keeps the working area clean from foreign debris Once the containment has been erected a thorough cleaning of the contained area should be
3. 50 of 32mm 1 25 1 0 Whipline connected to Up to 30m 100 of minimum 32mm 1 25 I D Blast Hose Extension which may be further connected to Up to an additional 30m 100 of 38mm 1 5 Blast Hose Extension Blast Hose lengths longer than 91m 300 are not recommended 7 2 Recommended Tools 6 Pliers small Hammer 10 Channel Locks 12 Pipe Wrench Grease gun and grease Pneumatic tool oil 10 Adjustable Wrench screw Drivers Regular and Phillips 10 T handle Hex Key 9 64 and 3 16 Wrenches 1 2 9 16 5 8 3 4 and 11 16 7 3 Recommended Spare Parts Complete Kits available from Sponge Jet 1 Exhaust Muffler 1 Air Motor 1 Auger Assembly 3 Nozzle Washers 1 Twinline Repair Kit 3 Hose Washers 1 Automatic Drain Kit 1 Timer 3 ft 5 32 pneumatic hose 3 ft 3 8 pneumatic hose 1 Control Valve 1 Desiccant Filter 1 Deadman Handle 2 Exhaust Valve Diaphragm 1 O ring for Secondary Water Separator Sponge Jet B VAC User Manual 10 February 2005 Page 26 of 55 ooo Sponge Jet Feed Unit _ Requirements Continued 7 4 Media Management Media Management is the way new and used sponge are added together while work is in process for best results and economy As sponge is blasted and recycled the sponge breaks down into smaller and more abrasive particles By adding and mixing new sponge with the used sponge the result will be that the larger particles of spong
4. 4 2 Turn the Secondary Vacuum Air Ball Valve to the on position 4 2 8 Load the B VAC with Sponge Media abrasives by vacuuming it through the vacuum nozzle 4 2 9 Check to see if the Emergency Stop Button E Stop is in the on position IMPORTANT E Stop and Deadman should not be engaged unless all operators are fully prepared to blast and the nozzle is under operator control oponge Jet B VAC User Manual 10 February 2005 Page 10 of 55 ooo 4 2 Starting the B VAC continued 4 2 10 Squeeze the Deadman Handle Trigger 4 2 11 Adjust Blast Pressure and Media Feed to recommended standard settings Note The recommended setting for industrial coating removal set the Blast Pressure to 6 5 bar 90psi and the Media Feed Pressure to 40psi oponge Jet B VAC User Manual 10 February 2005 Page 11 of 55 ooo Figures oponge Jet B VAC Pro 2 Figures B VAC Pro 2 Front Left 1 400 HP Sponge Jet Feed Unit 2 400 HP Cyclone Storage Silo B VAC Pro 2 Back Right 3 50 P Sponge Jet Recycler 4 50 P Recycler Cyclone Storage Silo 9 H E P A Vacuum 6 Oversized Waste Drum with locking lid 7 Fine Waste Drum with locking lid oponge Jet B VAC User Manual 10 February 2005 Page 12 of 55 B VAC Pro 2 Supplied Components 8 12 mm 5in 8 Blast Nozzle 9 Pneumatic Deadman Control 10 15m 50ft 32mm 1 25in 1 0 flexible Whipline with Twinline and fittings opo
5. at the Auger Figure D oponge Jet B VAC User Manual 10 February 2005 Page 33 of 55 Figure E Exhaust System 1 Exhaust Muffler The Exhaust Muffler reduces the noise caused by the air exiting the Feed Unit The Exhaust Muffler must be periodically emptied of Sponge Media and or other foreign debris 2 Exhaust Valve Diaphragm The Exhaust Valve Diaphragm regulates the release of air pressure from the Feed Unit when the Deadman Handle is released 3 Exhaust Valve The Exhaust Valve allows air contained in the pressure vessel to escape during depressurization 4 Exhaust Valve Cover The Exhaust Valve Cover secures the Exhaust Valve Diaphragm during operation of the Feed Unit Figure E Figure F Relief Valve Optional 1 Relief Valve The Relief Valve automatically releases air pressure from the pressure vessel when the internal air pressure exceeds 8 6 bar 125 psi Figure F oponge Jet B VAC User Manual 10 February 2005 Page 34 of 55 Figure Internal View 1 Pop Up Valve The Pop Up Valve seals the pressure vessel during blasting 2 Media Actuator The Media Actuator is a pneumatic motor that turns the actuator tree assembly inside the pressure vessel The media actuator assists in providing a continuous sponge media supply during blasting 3 Actuator Tree Assembly The Actuator Tree Assembly agitates sponge media in the pressure vessel 4 Actuator Chain The Actuator Chain assists in m
6. steel screen soldered to a 4 x 1 1 2 high tubular mesh ring top and one 1 16 mesh standard 018 wire diameter 044 open area stainless steel screen soldered to a 34 x 1 1 2 high tubular mesh ring Stainless Steel Parts Top 8 main rim angle with 6 long oversize chute amp finger scroll Bottom 15 x3 high deck section with scroll cone 6 op and oversize chute Motor GAST air motor Model 6AMNRV1A 4 Vane reversible The standard size for the Top Screen is 3 the Bottom Screen is 16 unless other sizes are specified or provided for differing throughput or particle size distribution For 24 hour technical service contact Sponge Jet Inc Technical Support at 603 431 6435 or in the USA 800 776 6435 In Europe please call 44 0 1253 390731 Sponge Jet B VAC User Manual 10 February 2005 Page 54 of 55 MODEL SERIAL Sponge Jet B VAC User Manual 10 February 2005 Page 55 of 55
7. visually inspected for holes wear and proper fit 7 The Port Hole Cover Fig 5 must be in place and secure prior to and during operation 8 Never point the Blast Nozzle Fig 3 towards yourself or others 9 Do not remove the Auger Chain Guard Fig J 2 to the Auger while the Feed Unit is in operation 10 If the optional Relief Valve Fig F 1 is activated contact Sponge Jet immediately at 800 776 6435 USA or 603 431 6435 Sponge Jet B VAC User Manual 10 February 2005 Page 14 of 55 oponge Jet B VAC User Manual 10 February 2005 4 0 Operation amp Shutdown 4 1 Operation of the Feed Unit Working temperature conditions for the BVAC should always be above freezing Inspect the Blast Nozzle Fig 3 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 and ensure that it is equipped with a Nozzle Washer Replace the Blast Nozzle and Nozzle Washer insuring that the Nozzle Washer lies flat in its seat Visually inspect all Blast Hose Fig 1 and connections Repair or replace any worn or damaged components Ensure that all couplings are equipped with coupling gaskets and safety pins or hose restraints and that they are all properly installed Connect the compressor to Feed Unit Supply Line Connection Fig B 9 and secure with safety pins or restraints Sponge Jet su
8. 1 tubular mesh rings See section 5 5 Sieve Assembly for proper screen installation 6 Double Deck Main Rim with Reusable Media Downspout Particles that do not fall through the Bottom Screen are discharged through the Reusable Media Downspout 7 Shallow Funnel with Fine Particle Downspout Located under the Bottom Screen the shallow funnel collects and directs fine particulate into the Fine Particle Downspout which are discharged through the Downspout Sponge Jet B VAC User Manual 10 February 2005 Page 50 of 55 Figure B Main Controls 1 AirFilter The Air Filter is intended to protect the Air Motor and Regulator from damage due to dirty or wet air 2 Regulator Regulates the airflow 3 Lubricator Contains oil used to disburse moisture and lubricate the Air Motor 4 Air Inlet Valve The Air Inlet Valve is the main air control valve that starts and stops the airflow to the Pneumatic Media Classifier 5 Muffler Located on the Air Motor Figure B 6 2 Pressure Gauge Measures the output pressure of the Regulator 7 Bracket Located on the outside of the housing This Bracket holds the Filter Lubricator Pressure Gauge and Regulator Sponge Jet B VAC User Manual 10 February 2005 Page 51 of 55 Figure C Vibratory Portion and Lower Base Assembly 1 Weight This off center weight causes the upper eccentric Flywheel to move media across the screen Side Cover This removable cove
9. 27 of 55 Sponge Jet Feed Unit Requirements Continued 1 5 Media Uses and Approximate Settings The settings and descriptions below are approximate Individual applications and uses will vary BP Blast Pressure MFP Media Feed Pressure Green Sponge Media General contaminant cleaning 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 Slight Etch White Sponge Media Paint removal from composites Paint removal on delicate metallic substrates Tenacious contaminate removal Mold cleaning of baked on residues Settings BP 2 1 4 1 bar 30 60 psi MFP 1 7 3 1 bar 25 45 psi Profile Generated Not applicable de glossing occurs Brown Sponge Media Light paint and contaminant removal Clean and profile existing paint for recoating Paint de glossing Settings BP 2 1 5 9 bar 30 85 psi MFP 1 4 3 1 bar 20 to 45 psi Profile Generated 25 50 microns 1 2 mils Silver Sponge Media Paint and contaminant removal on steel Paint and contaminant removal on aluminum Paint and contaminant removal on concrete masonry and block General surface preparation activities Rust and mill scale removal Char removal Settings BP 2 8 5 9 bar 40 85 psi MFP 1 4 3 1 bar 20 45 psi Profile Generated 63 113 microns 2 5 4 5 mils
10. 4 This special diagnostic activity should only be performed under the direct guidance of a Sponge Jet Technical Service Representative 1 Turn the Blast Pressure Regulator Handle Fig B 5 counter clockwise to the off position by rotating the handle until the handle is removed from the body of the valve 2 urn the Media Feed Pressure Regulator Handle Fig B 6 counter clockwise to the off position by rotating the handle until the handle is removed from the body of the valve 3 Remove Port Hole Cover Fig A 5 and evacuate enough abrasive media in the Pressure Vessel so that the Media Actuator Fig 2 and the Actuator Tree Assembly Fig G 3 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 90 degrees alternating direction every 1 2 seconds The components should not rotate beyond 90 degrees 6 15 Air flows through Blast Nozzle but with no media in the air stream and the Auger is rotating 1 Adjust the panel to the Non Blasting Mode 6 14 2 Remove top orange output airline on the Desiccant Filter Fig 2 depress the Deadman Handle Fig H 46 and check for airflow from top of Desiccant Filter which should be continuous 6 16 If no airflow is felt from the top of the Desiccant Filter 1 Repl
11. 6 with the Main Air Ball Valve Fig B 8 open and the Feed Unit pressurized 2 Listen for an exhaust of air from behind the Deadman Handle when handle is released 3 Ifan exhaust of air is heard but the Feed Unit will not run skip to Step 6 3 4 Ifan exhaust is not heard confirm you are using a Sponge Jet approved Deadman Handle and call Sponge Jet Inc Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 6 3 If an exhaust of air is heard when the Deadman Control is released 1 Remove the Red Air Line from the Exhaust Valve Fig E 3 2 While holding the Red Air Line securely depress the Deadman Handle Fig 6 and feel for a blast of air at the Red Air Line Sponge Jet B VAC User Manual 10 February 2005 Page 19 of 55 Qoo Troubleshooting continued 6 4 If air is felt flowing through Red Air Line 1 Stop flow of air from Red Air Line by placing thumb over opening This will test for a possible ruptured Exhaust Valve Diaphragm Fig E 2 If Feed Unit does not start up skip to Step 6 5 If Feed Unit does start up remove thumb from Red Air Line Replace the Exhaust Valve Diaphragm Cer x coe dq Test Feed Unit for proper operation and resume blasting 6 5 If Feed Unit does not start up 1 Close Main Air Ball Valve Fig B 8 and allow Feed Unit to depressurize 2 Replace On Off Control Valve Fig C 1 3 Test Feed Unit for proper operation and resume blasting
12. 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 3 for wear Once the nozzle bore has worn 2mm 1 16 beyond its original intended diameter it should be replaced e Remove the Blast Nozzle and ensure that it is equipped with a nozzle washer between the nozzle and its holder Reinstall the nozzle and washer taking care to see that the washer lies flat in its seat e Visually inspect all Blast Hose Fig H 1 and connections Repair or replace any worn or damaged components Ensure that all couplings are equipped with coupling gaskets and safety pins and that they are properly installed e Inspect and clean the Exhaust Muffler Fig E 1 Remove any accumulated media from within it and reinstall WARNING Do not operate equipment without muffler in place 9 2 The following maintenance should be performed after each 80 hours of operation e Remove and inspect the interior of the Secondary Water Separator Fig B 10 Remove any contaminants that have accumulated in the bowl Reinstall e Visually inspect the ring on the Secondary Water Separator and Air Motor Moisture Separator Fig D 2 Replace if the O ring has been damaged or worn 5 3 The following maintenance should be performed monthly e Remove Auger Chain Guard Fig J 2 inspect the condition of the Auger Drive Chain Fig J 5 Apply light
13. Fig A 7 3 Place the Stainless Steel Ring Clip Fig A 5 with the 16 mesh screen attached Important Place mesh screen up into the Shallow Funnel and on top of the Flat Gasket oponge Jet B VAC User Manual 10 February 2005 Page 45 of 55 ooo 4 a Flat Gasket onto the Stainless Steel Ring Clip making sure to center the Flat Gasket 5 Place the Double Deck Main Rim with Reusable Media Downspout Fig A 46 over the Flat Gasket and Stainless Steel Ring Clip and into the Shallow Funnel 6 Place a Flat Gasket into the Double Deck Main Rim 7 Place the Stainless Steel Ring Clip with the 73 mesh screen attached IMPORTANT Place mesh screen side up into the Double Deck Main Rim and on top of the Flat Gasket 8 Place a Flat Gasket onto the Stainless Steel Ring Clip making sure to center the Flat Gasket 9 Place the Feeding Ring Hopper over the Flat Gasket making sure that the Large Particle Downspout Fig A 3 is opposite from the Reusable Media Downspout Fig A 6 10 Attach the Pan Clamps Fig D These must be closed to secure the Sieve Assembly The typical size for the Top Screen is 3 the Bottom Screen is 16 other sizes may be provided for differing throughput or particle size distribution IMPORTANT All screens must be assembled with mesh on the top Incorrect fitting is an easy mistake and will cause the Pneumatic Media Classifier to operate unsatisfactorily Sponge J
14. Sponge Jet Sponge Blasting System Sponge Jet User Manual Model B VAC B VAC Pro B VAC Pros Sponge Jet Inc USA esoo oby 9 7 235 Heritage Ave Ste 2 id Portsmouth NH 03801 tel 603 431 6435 www spongejet com oponge Jet B VAC User Manual 10 February 2004 Page 1 of 55 ooo II EEE EEE 1 0 Introduction 1 1 Basic Components and Parts Inventory 1 400 HP Sponge Jet Feed Unit 1 400 HP Cyclone Storage Silo 490L 1 50 P Sponge Jet Recycler 1 50 P Recycler Cyclone Storage Silo 340L 1 H E P A Vacuum 2 Ribbed Reinforced 18 gauge Waste Drums with locking lid 1 12 mm 5in 8 Blast Nozzle 1 15m 50ft 32mm 1 25in I D flexible Whipline with a Pneumatic Deadman Control Twinline and Fittings 1 15m 50 clear vacuum hose 1 2 Basic Operation 50 CYCLONE STORAGE SILO I SPONGE MEDIA 90 P pod RECYCLER 400 HP 3 rz CYCLONE STORAGE OVERSIZED n SILO WASTE d FINE waste 400 HP VACUUM FEED UNIT HEAD BLAST NOZZLE AIR FLOW ONLY 7 MIXED AIR STREAM oponge Jet B VAC User Manual 10 February 2005 Page 2 of 55 1 1 Warning 1 The use of bleeder type Handle handles may cause unintentional start up without warning which can result in personal injury 2 his equipment is designed for operation with clean dry compressed air in temperatures above freezing 3 o prevent electrostatic buildup and p
15. The Hopper Lid prevents any foreign debris from entering the Feed Unit should be placed on the hopper during Feed Unit operation 2 Hopper Located under 400 HP Cyclone Storage Silo The Hopper holds the reserve Sponge Media for the Feed Unit 3 Lifting Lugs B VAC Lifting Lugs and Pad Eyes are available on the B VAC PRO 2 Frame 4 Pressure Vessel The Pressure Vessel is where sponge media is stored during blasting 5 Port Hole Cover The Port Hole Cover allows access to the inside of the pressure vessel 6 Twinline Quick Connect Fittings The Twinline Quick Connect fittings attach the twinline from the Deadman Handle to the Feed Unit T Crab 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 T L a A E 6 1 a p oponge Jet B VAC User Manual 10 February 2005 Page 30 of 55 Figure Control Panel Figure B Figure C oponge Jet B VAC User Manual 10 February 2005 Figure B 1 Emergency Stop Button The Emergency Stop Button stops the Feed Unit instantly when depressed 2 Blast Pressure Gauge The Blast Pressure Gauge indicates the amount of pressure exiting the Feed Unit The recommended pressure for effective coatings removal and optimal media reuses is 6 2 bar 90 psi or less 3 Media Feed Pressure Gauge The Medi
16. a Feed Pressure Gauge indicates the amount of air pressure being supplied to the Air Motor This in turn relates to how much Sponge Media that is introduced into the air stream The recommended pressure for optimal coatings removal is 1 4 2 8 bar 20 40 psi 4 Line Pressure Gauge The Line Pressure Gauge indicates the amount of pressure entering the Feed Unit from the compressor The recommended inbound pressure is 8 bar 120 psi 5 Blast Pressure Regulator Handle The Blast Pressure Regulator Handle allows for the adjustment of airflow to the Blast Nozzle 6 Media Feed Pressure Regulator Handle The Media Feed Pressure Regulator Handle allows the pot tender to regulate the amount of media provided to the airline for blasting T Agitation Indicator Eye The Agitation Indicator Eye shows the rate at which the Sponge Jet Actuator Tree Assembly is actuating within the pressure vessel 8 Main Air Ball Valve The Main Air Ball Valve starts and stops the airflow from entering the Feed Unit This device is not a regulation device 9 Supply Line Connection The Supply Line Connection uses a four prong Chicago fitting on a 51mm 2in National Pipe Thread NPT nipple 10 Secondary Water Separator The Secondary Water Separator separates water from the air stream with an 80 micron filter Page 31 of 55 Figure C oponge Jet B VAC User Manual 10 February 2005 Figure C 1 On Off Control Valve The On Off Control Valv
17. ace the Desiccant Filter Fig 2 noting the position of the airlines when replacing the filter It is necessary to switch airline fittings from old filter to new 2 Re test for airflow and check for proper motion of the Agitation Indicator Eye Fig B 7 When operating properly a light pulse of air can be felt exiting from the top of the Timer Fig I 3 3 Resume blasting Sponge Jet B VAC User Manual 10 February 2005 Page 23 of 55 ooo Troubleshooting continued 6 17 If no pulse of air is felt at the top of the Timer 1 Check that the Timer Fig I 3 is set properly at 2 75 for the 400L Reset if necessary 2 Testfor pulse of air and check for proper motion of the Agitation Indicator Eye Fig B 7 and Actuator Tree Assembly Fig G 3 3 Resume blasting 6 18 If air is still not felt at the top of the Timer 1 Remove the 2 screws on face of the Timer Fig 3 and replace the Timer making sure to note the position of the hoses on the back of the Timer 2 Test the new Timer for pulse of air and check for proper motion of the Agitation Indictor Eye Fig B 7 and the Actuator Tree Fig G 3 Resume blasting 6 19 If a pulse of air is felt at the top of the Timer but media flow is still not present or consistent 1 With the Deadman Handle Fig 6 depressed observe that the Agitation Indicator Eye Fig B 7 is blinking and appears to be working 2 If not call Sponge Jet Technical S
18. al that activates the Actuator Tree Assembly oponge Jet B VAC User Manual 10 February 2005 Page 37 of 55 ooo Figure J Lower End Left Side View 1 Air Motor The Air Motor through adjustment at the control panel regulates the air media mixture by turning the Auger 2 Auger Chain Guard The Auger Chain Guard prevents injury from contact with the drive chain 3 Clean Out Trap The clean out trap catches foreign debris not meant to pass through the nozzle The clean out trap must be periodically emptied of all debris 4 Auger Manual Rotation Handle Handle used to turn Auger to check for Auger jams 5 Auger Drive Chain The Auger Drive Chain in conjunction with the Auger Sprocket rotates the Auger Shaft 6 Auger Sprocket The Auger Sprocket drives the Auger T Air Motor Sprocket The Air Motor Sprocket drives the Auger Drive Chain 8 Auger The Auger feeds Sponge Media abrasives into the air stream Figure J oponge Jet B VAC User Manual 10 February 2005 Page 38 of 55 IIE Vg asssct2k2 sse 1 0 Recycler Introduction The Pneumatic Media Classifier separates large and small foreign matter from reusable Sponge Media abrasives A specially weighted rotating spindle oscillates spent Sponge Media abrasives and surface contaminants through two screens and classifies the materials for separate collection Designed for industrial durability the Pneumatic Media Classifier can pro
19. and the Media Feed Pressure Regulator Handle Fig B 6 to the desired levels Clockwise adjustments increase pressures Do not exceed a Blast Pressure Gauge reading of 6 2 bar 90 psi Adjust the Media Feed Pressure Gauge to the desired level usually 2 8 bar 40 psi for initial operation using the Media Feed Pressure Regulator Handle Confirm that the Blast Pressure Gauge remains at the desired level Once the desired Blast Pressure Gauge and Media Feed Pressure Gauge levels are obtained visually confirm that the Auger Fig J 8 is rotating and that the Agitation Indicator Eye Fig B 7 is functioning These levels should remain constant unless adjusted sponge Blast the desired surface 4 2 Shutdown of the Feed Unit The red Emergency Stop Button Fig B 1 is located on the Control Panel Fig B inset can be used to stop all functions Normal shutdown during operation is by release of the Deadman Handle Fig 6 Close the Main Air Ball Valve Fig B 8 shut down the compressor and depressurize as directed by manufacturer Close the supply line ball valve at the compressor and the Main Air Ball Valve at the Feed Unit Compressor supplied by others Once the supply of air from the compressor to the Feed Unit has been closed open the Main Air Ball Valve at the Feed Unit Point the Blast Nozzle Fig 3 at the working substrate away from people and depress the Deadman Handle Fig 6 Keep the Deadman Han
20. cause irrevocable damage to this part Sponge Jet B VAC User Manual 10 February 2005 Page 42 of 55 4 0 Normal Operation 4 1 Feed Connections IMPORTANT It is essential not to restrict the movement of the vibrating portion of the machine It is recommended that no rigid connections be added to the inlet outlet of the Pneumatic Media Classifier Rigid connections can reduce the efficiency of the Pneumatic Media Classifier and lead to early fatigue of the sheet metal parts and weldments 4 2 Adjustment of Pan Clamps The Pan Clamps Fig D have a simple adjustment that allows for different thickness Flat Gaskets Fig A 4 Adjustment is made by turning the Steel Hook Top Fig D 4 Under normal operation adjustment should not be necessary if all pans and gaskets are in the proper location Pressure required to close the four 4 Pan Clamps should not exceed five 5 pounds each at the end of the lever Handle Fig D 1 A Lock Nut Fig D 3 behind the Steel Hook Top should be tightened just enough to prevent the Steel Hook Top from turning when dismounting portions of the Sieve Assembly WARNING DO NOT APPLY EXCESSIVE FORCE WHILE TIGHTENING THESE CLAMPS THE VIBRATION OF THE CLASSIFIER WILL CAUSE THE OVERTIGHTENED CLAMPS TO BREAK oponge Jet B VAC User Manual 10 February 2005 Page 43 of 55 oponge Jet B VAC User Manual 10 February 2005 5 0 Advanced Operation Important Before operation
21. cess up to 800 pounds 350 kgs of foreign matter and Sponge Media abrasives per hour Inspection of the Pneumatic Media Classifier will reveal it to be of relatively simple design As a result few parts are subject to wear under normal operating conditions Note During operation the Lower Base Assembly Fig C 6 experiences very little vibration This base supports the Vibratory Portion Fig C 7 and the Sieve Assembly Fig A of the Pneumatic Media Classifier The Pneumatic Media Classifier is powered by an air operated motor Energy is directly transmitted through the flywheel shaft The Sieve Assembly Fig A of the Pneumatic Media Classifier sits inside the Vibratory Portion Fig C 7 and is secured by four 4 heavy duty clamps called Pan Clamps Fig D The entire Sieve Assembly and Vibratory Portion is isolated from the Lower Base Assembly by three 3 Suspension Rods Fig C 5 and consists of the following illustrated in Fig Dome Lid with Inlet Screens mounted to Stainless Steel Ring Clips Flat Gaskets and Media Downspouts In the center of the Vibratory Portion is an eccentric Flywheel Fig C 4 The vibratory energy generated directly by this Flywheel is transmitted to the Sieve Assembly Beneath the flywheel housing and located on the lower end of the shaft is an adjustable eccentric weight When this weight rotates the upper eccentric Flywheel causes the media to move across the screen in a horizonta
22. dle depressed until all remaining air is vented from the Feed Unit and the Blast Hose Fig 1 oponge Jet B VAC User Manual 10 February 2005 Page 16 of 55 ooo Operation amp Shutdown Once all gauges on the Feed Unit Control Panel Fig B inset read 0 PSI continued confirm that the supply line from the compressor is soft amp pliable If the prior steps have been followed exactly the supply line from the compressor to the Feed Unit should now be vented and safe to disconnect WARNING Before disconnecting the compressor supply line ensure that all gauges on both the Feed Unit and the Compressor register 0 PSI Allowing for adequate evacuation time as well as determining hose pliability are important safety precautions that must be utilized when disconnecting any high pressure air supply line e fthe Feed Unit is to remain out of service for more than one day remove by vacuum all residual media through from inside the Pressure Vessel Fig 4 of the Feed Unit and the Hopper Fig 2 e heresulting product of process must be disposed of in accordance with local and or Federal regulations governing waste disposal oponge Jet B VAC User Manual 10 February 2005 Page 17 of 55 oponge Jet B VAC User Manual 10 February 2005 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
23. e Particle Downspout of 50 P Recycler to the locking lid of a Waste Drum 2 1 2 Connect Vacuum Hose from the Fine Particle Downspout of 50 P Recycler to the locking lid of a Waste Drum y UI I pes E 4 E L 1 EF J E 3 k E z en d i T e hi 5 Me 5 4 ri SY UN 8 Vu ie mel E F ys a m m LI PL Y 2 1 3 Connect the outbound Vacuum Hose to the 50 P Recycler Cyclone Storage Silo Page 4 of 55 oponge Jet B VAC User Manual 10 February 2005 2 2 Connecting Hoses 2 2 1 Insert Whipline through the Pinch Valve and connect it to the Blast Hose Connection 2 2 2 Attach the Twinline Connect Fittings to the corresponding Twinline Connect Fittings mounted on the B VAC 2 2 3 Connect the Bull Hose from the Compressor to the Supply Line Connection using the following procedures 1 Connect the Bull Hose Safety Restraint Note Not supplied by Sponge Jet looping it around each coupling and then tightening it in place 2 Connect the Bull Hose Coupling and Supply Line Connection Coupling by bringing the two coupling seals together and rotate clock wise to lock 3 Insert the Safety Pin in the lip of both couplings Page 5 of 55 3 0 Operational Requirements 3 1 Air Requirements 3 1 1 21 25 m min 750CFM C
24. e serves as the Feed Unit s on off switch When the On Off Control Valve is open blasting is initiated When the On Off Control Valve is closed the Feed Unit is depressurized and turns off 2 Blast Pressure Regulator The Blast Pressure Regulator regulates the amount of airflow traveling through the Feed Unit and out to the nozzle 3 Control Panel Moisture Separator The Control Panel Moisture Separator is intended to remove any remaining water or other liquid contaminants from the sensitive control panel instrumentation Page 32 of 55 Figure D Lower End 1 Choke Valve The Choke Valve is normally fully open The Choke Valve when closed directs the air stream through the Pressure Vessel and can be used to clean out the Feed Unit The choke valve in the closed position causes sponge media to quickly exit the Feed Unit 2 Air Motor Moisture Separator The Air Motor Moisture Separator which automatically drains when full protects the air motor from excess moisture 3 Air Motor Lubricator The Air Motor Lubricator injects oil automatically from a reservoir into the air stream 4 Auger Tunnel End Cap The Auger Tunnel End Cap allows access to the auger for cleaning purposes 5 Blast Hose Connection The Blast Hose Connection is a two pronged universal Blast Hose connector fitting which allows for connection from the Blast Hose to the Feed Unit 6 Clean Out Trap The Clean Out Trap is removable to check for obstructions
25. e should increase If Air Motor Fig J 1 sticks at startup or becomes sluggish at lower pressures it may be necessary to add pneumatic hand tool oil to the Air Motor Lubricator Fig D 3 The Air Motor chronically starts with difficulty becomes sluggish or seizes completely it may need to be rebuilt Sponge Jet Inc offers a rebuild service Call Sponge Jet Inc at 800 776 6435 USA or 603 431 6435 for details 6 9 Auger stops rotating during normal operation 1 Stop blasting depressurize the Feed Unit close the Main Air Ball Valve Fig B 8 and depress the Emergency Stop Button Fig B 71 2 Rotate Auger Manual Rotation Handle Fig J 4 by hand only 1 3 rotations clockwise 3 Ifthe Auger Manual Rotation Handle will not turn by hand remove the Clean Out Trap Fig D 6 and rotate the auger back and forth until the obstruction falls out 4 Replace the Clean Out Trap Rotate Auger Manual Rotation Handle to make sure that the Auger Fig J 8 is free of obstruction 5 Resume blasting Return the media feed pressure to its desired level between 2 8 bar 40 psi If the auger still does not rotate call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 6 10 Air Flow Through Nozzle Suddenly Stops 1 Stop any attempt to restart and depress the Emergency Stop Button Fig B 1 immediately Depressurize the Feed Unit and close the Main Air Ball Valve Fig B 8 2 Remove Blas
26. e will suppress the dust generated by the fast cutting used sponge This mixture of new and used sponge is called the working mix All blasting applications will require specific consumption analysis As a rule of thumb Using a 1 2 8 Nozzle 1 2 bag of new Sponge Media abrasive should be added to the working mix every 30 minutes of nozzle blast time 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 Fines can be reused in some circumstances by adding a portion of the fines generated back into the working mix described above The exact amount of fines reintroduced will be determined by how much dust can be tolerated in the work area Many users find other uses for fines For example a contractor used silver media on the superstructure of a paper machine to remove paint corrosion and contaminates As the Silver Sponge Media abrasive broke down the contractor saved the fines in 250L 55 gallon drums Once a year at this particular paper mill each boiler is shut down for cleaning Dust levels are not a significant problem inside the boiler therefore Silver Sponge Media abrasive fines were utilized as a cleaning abrasive within the boiler WARNING Fines should not be reused when working with hazardous substances such as lead paint oponge Jet B VAC User Manual 10 February 2005 Page
27. ease ambient dust levels at the work site Important The acceptability of increased dust levels is usually established within the responsibilities of each project superintendent Usually undersize particles are considered waste Hazardous materials such as but not limited to lead paint chromates radionuclide cadmium or PCB s can present special demands upon the user to manage the waste stream according to best practices and all applicable regulations The standard size for the Top Screen is 3 the Bottom Screen is 16 unless other sizes are specified or provided for differing throughput or particle size distribution With reasonable care and maintenance the Pneumatic Media Classifier is a reliable efficient part of the Sponge Blasting System Questions that arise may be addressed to Sponge Jet Inc s 24 Hour Technical Support at 603 431 6435 or in the USA 800 776 6435 In Europe please call 44 0 1253 390731 Sponge Jet B VAC User Manual 10 February 2005 Page 41 of 55 ooo 3 0 Air Requirements Compressed air is the source of energy for the Pneumatic Media Classifier allowing it to be used independent of electric power oponge Jet requires a minimum of 35cfm 1 m min with a factory set pressure limit not to exceed 30psi 2 Bar An Air Filter Fig B 1 provided on the inlet side of the Pneumatic Media Classifier is intended to protect the Air Motor Fig C 3 from damage due wet air which can
28. ervice at 800 776 6435 USA or 603 431 6435 for further assistance 3 fit does appear to be blinking reduce the blast pressure to 0 bar O psi on the Blast Pressure Gauge Fig B 2 using the Blast Pressure Regulator Handle Fig B 5 4 Reduce the Media Feed Pressure to 0 psi by turning the Media Feed Pressure Regulator Handle Fig B 6 counter clockwise 5 Open the Port Hole Fig 5 cover to the blast pot 6 Depress the Deadman Handle Fig 6 and observe the activity of the Actuator Tree Assembly Fig G 3 It should rotate 90 degrees in both directions with motion occurring about every two seconds 7 If it still does not operate call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance Sponge Jet B VAC User Manual 10 February 2005 Page 24 of 55 7 0 Sponge Jet B VAC Requirements Equipment and Air requirements 1 0 Inner Diameter 0 D Outer Diameter 7 1 B VAC A Compressor 21 2 m min 750 CFM minimum at 7 6 bar 110 psi for a 8 nozzle 16mm 1 2 SEE BELOW FOR OTHER NOZZLE AIR REQUIREMENTS 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 de
29. et B VAC User Manual 10 February 2005 Page 46 of 55 oponge Jet B VAC User Manual 10 February 2005 6 0 Routine Maintenance IMPORTANT Under NO circumstances should any inspection adjustment or lubrication be conducted while the Pneumatic Media Classifier is running or connected to an air supply 6 1 Lubrication Pneumatic Media Classifiers have been tested before shipment DO NOT grease this Pneumatic Media Classifier until it has been operated for 500 hours Re lubricate using a pump or small amount every 500 hours of operation DO NOT OVERGREASE Recommended Lubricants are Citco AP Citco oil Ore Lube K2 Mobilux Grease 2 Socony Mobil Oil Co Val Lith 1 Valvoline Co VS SGA MM Industries Inc Multifak 2 Texaco Inc 7 Alvanie R Shell Oil Co A N WARNING DO NOT FORCE EXCESSIVE GREASE Damage could occur to the bearings and air motor system 6 2 Access to Grease Fittings 1 Ihetwo 2 bearings are greased by access through the grease fittings on the side of the machine IMPORTANT If the machine has not been used for one year add 1 to 2 pumps of grease 6 3 The Lubricator It is important to check the levels of the oil in the Lubricator Fig B 3 If necessary refill with Pneumatic Hand Tool Oil Refill by unscrewing the bottom portion of the lubricator being careful not to spill the remaining oil IMPORTANT If any undue noise is detected please n
30. if any substantial disassembly has occurred to the Pneumatic Media Classifier it is important to verify the following has been completed 5 1 Amplitude of Vibration Adjustment during the use of the machine should be kept to a minimum The one variable with which the operator should be concerned is the amplitude of vibration The Pneumatic Media Classifier has one 1 Flywheel Fig C 4 which is adjustable to five 5 varying degrees of off center This adjustment will modify horizontal amplitude Located below the Flywheel housing on the flywheel shaft is an adjustable weight When the weight is set off center from the upper flywheel weight varying amounts of vertical deflection occur This deflection is also a function of the RPM from the Flywheel 5 2 Procedure for Adjustment of Amplitude Adjust the Flywheel as follows 1 Remove the Sieve Assembly to expose the top bearing housing bracket 2 n the bracket there will be a 1 2 thru hole Rotate the Flywheel until the socket head cap screw comes into view Amplitude setting numbers will range from 1 to 3 3 Remove this screw until Flywheel slide weight can be rotated to the desired setting number 4 Tighten the screw securely second adjustment is available by moving the kicker weight To adjust the kicker weight remove the Side Cover Fig C 2 The kicker weight is located directly above the upper coupling flange One 1 bolt holds the fan shaped
31. l standard 3 mesh screen used to separate unwanted foreign matter larger than a particle of Sponge Media abrasive Items such as nuts bolts or rocks are separated and discharged as oversized particles through the Large Particle Downspout Fig A 3 WARNING Oversize particles if re introduced back into the Working Mix can be damaging as they could 1 become a projectile capable of injuring people 2 harm the work surface 3 pierce a pressurized blast hose 4 clog the Feed Unit and or 5 damage or jam the drive mechanism oponge Jet B VAC User Manual 10 February 2005 Page 40 of 55 ooo 2 2 Reusable Media oponge Media abrasives that do not pass through the Bottom Screen exit the Pneumatic Media Classifier via the Reusable Media Downspout Fig A 6 Sponge Media abrasive that exits this downspout can be reused in the Sponge Jet Feed Unit 2 3 Bottom Screen Fine Particle Classification The Bottom Screen Fig A 5 is a stainless steel number 416 mesh screen used to separate foreign matter smaller than most Sponge Media particles Fine particles are separated from Sponge Media and discharged through the Fine Particle Downspout Fig A 7 as undersize particles and are normally considered waste Fine particles usually include paint chips broken down spent abrasive and separated urethane particles These fine particles if reintroduced to the Sponge Media abrasive Working Mix will incr
32. l direction Sponge Jet B VAC User Manual 10 February 2005 Page 39 of 55 2 0 Media Classification IMPORTANT It would be difficult to overemphasize the importance of separating oversize and undersize particles from reusable Sponge Media abrasive Proper separation is critical to reducing airborne dust and minimizing the risk of obstructing the Sponge Jet Feed Unit while blasting The Media Classification Process in Brief 1 After connecting the Pneumatic Media Classifier to an adequate air supply see section 3 0 Activate the Pneumatic Media Classifier by opening the Air Inlet Valve Fig B 4 oponge Media abrasive is added through the Dome Lid Inlet Fig A 1 located on the top of the Pneumatic Media Classifier Reusable Sponge Media abrasive and small contaminants pass through the Top Screen Fig A 2 Oversize particles are carried over the screen and out the Large Particle Downspout Fig A 3 oponge Media abrasive and any remaining contaminants pass down to the Bottom Screen Fig A 5 where reusable Sponge Media abrasive is carried over the bottom screen and exits the Pneumatic Media Classifier via the Reusable Media Downspout Fig A 6 omaller contaminants and spent media abrasives fall below the Bottom Screen as undersized particles and are ejected through the Fine Particle Downspout Fig A 7 2 1 Top Screen Large Particle Classification The Top Screen Fig A 2 is a stainless stee
33. lean Air Compressor 3 1 2 In bound pressure of 8 6Bar 125psi 3 2 Air Temperature 3 2 1 Ambient temperature above 0 Celsius 32 Fahrenheit O 32 F 3 3 Safety Precautions 3 3 1 Use body eye hearing and hand protection with appropriate respiratory equipment necessary to comply with local state or province and national health and safety regulations B oponge Jet B VAC User Manual 10 February 2005 Page 6 of 55 ooo 4 0 Equipment Operation 4 1 Before Starting the B VAC 4 1 1 Turn the Main Air Ball Valve to the off position 4 1 2 Turn the Primary Vacuum Air Ball Valve to the off position oponge Jet B VAC User Manual 10 February 2005 Page 7 of 55 oponge Jet B VAC User Manual 10 February 2005 4 1 Before starting the B VAC continued 4 1 4 Turn the Primary Recycler Air Ball Valve to the off position 4 1 5 5 Turn the compressor off 4 1 6 Turn the Compressor Air Ball Valve in the off position Page 8 of 55 ooo ONS EE EEE 4 2 Starting the B VAC 4 2 1 Turn the Compressor on per manufacturer s instructions 4 2 2 Turn the Compressor Air Ball Valve in the on position 4 2 4 Turn the Primary Recycler Air Ball Valve to the on position oponge Jet B VAC User Manual 10 February 2005 Page 9 of 55 ooo 4 2 Starting the B VAC continued 4 2 6 Turn the Primary Vacuum Air Ball Valve to the on position
34. nge Jet B VAC User Manual 10 February 2005 Page 13 of 55 ooo 3 0 Safety Note 1 8 6 bar 125 psi sustained maximum inbound pressure The Sponge Jet Inc Feed Unit is a pressurized positive air feed system Only certified operators should adjust maintain and repair this equipment oponge Jet offers a certification program to train operators in the mechanics of the equipment as well as in Sponge Blasting applications 1 Use Sponge Jet approved positive feed Deadman Handle Fig 6 2 Before performing any maintenance on the Feed Unit make sure equipment is off and depressurized The Main Air Ball Valve Fig B 8 and the Emergency Stop Button Fig B 1 on the Control Panel Fig B inset should both be in the off position to insure the Feed Unit is not accidentally pressurized 3 From the compressor under normal circumstances the inbound pressure should never exceed 8 6 bar 125 psi The pressure can be checked at the compressor or by the Blast Pressure Gauge Fig B 2 on the Control Panel 4 When operating the BVAC people in proximity should always wear eye and hearing protection with the appropriate respiratory equipment which may depend on the type of coating or contaminate being removed 5 Prior to pressurizing the Feed Unit safety pins or restraints should be fitted at all Bull Hose and Blast Hose couplings to prevent accidental disconnection 6 Before blasting all pneumatic lines should be
35. operating If the Agitation Indicator Eye is not changing call Sponge Jet Technical Service at 800 776 6435 USA or 603 431 6435 for further assistance 3 After depressurizing the system in accordance with Section 4 2 open the Port Hole Cover Fig A 5 and check that Actuator Tree Assembly Fig G 3 is attached to Media Actuator Fig G 2 Reconnect if necessary 6 12 Too much media exits the Nozzle and or media is pulsing out of nozzle 1 Check that the Choke Valve Fig D 1 is in full open position e g parallel to pipe Open if necessary and continue 2 Check the Media Feed Pressure Gauge Fig B 3 is not set above 3 4 Bar 50 psi if so reduce the pressure as necessary 3 Resume Blasting 6 13 Blast Pressure increases amp decreases continuously or Feed Unit exhausts intermittently while blasting 1 Check for holes in Twinline Fig H 4 and check for air leaks at all fitting connections Repair replace or tighten as necessary 2 Remove Exhaust Valve Cover Fig E 4 inspect for obstructions and check inner gasket for rips or any small holes Clean or replace as necessary 3 Resume Blasting Sponge Jet B VAC User Manual 10 February 2005 Page 22 of 55 ooo Troubleshooting continued 6 14 Panel testing in the non blasting mode This procedure will help to diagnose possible component problems on the Control Panel Fig B inset and in the Actuator system within the Pressure Vessel Fig
36. osen two 2 3 8 16 set screws Remove Flywheel Loosen ten 10 3 8 16 set screws Loosen one 1 7 16 hex head cap screws from ends of shaft Loosen two 2 3 8 16 socket head cap screws Remove upper coupling flange Remove ten 10 3 8 16 socket head cap screws and grease line Remove flywheel housing from top sieve weldment Page 48 of 55 12 Loosen 1 4 cap screws remove Flywheel top cap and bottom cap 13 Slide Flywheel shaft with bearings through bottom of housing 14 Remove circlip Press bearing from shaft 15 Press outside race of roller bearings from flywheel housing 16 Remove seals from top and bottom caps 17 Clean and inspect all parts for wear deburr all parts as required 18 Follow steps 1 through 16 to in reverse order to reassemble IMPORTANT Follow steps for proper alignment after assembly Sponge Jet B VAC User Manual 10 February 2005 Page 49 of 55 ooo FIGURES Figure A Sieve Assemhly 1 Dome Lid with Inlet oponge Jet Media enters through inlet from Cyclone 2 Stainless Steel Ring Clip Top Screen Mesh Screens are mounted to the Stainless Steel Ring Clips 3 Large Particle Downspout Oversized particles that cannot pass through the top screen are discharged through the Large Particle Downspout 4 Flat Buna Gaskets Reuires Four 22 flat buna rubber gaskets 5 Stainless Steel Ring Clip Bottom Screen Mesh screens are mounted to these 2 X
37. ossible electric discharge the unit and work piece must be properly bonded and grounded 4 Recommended inbound Line Pressure should be between 7 5 8 25 110 120psi with maximum inbound Line Pressure limited to 8 6 bar 125psi and is regulated at the compressor Connecting unit to a compressed air source exceeding the recommended pressure is not only dangerous but may also damage the pressure regulation devices in the Sponge Jet Sponge Blasting System 9 he maximum output or outbound Blast Pressure should be limited to 6 5 bar 90psi and is regulated on the Feed Unit 6 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 Moisture Separator Automatic Drain Offs must remain free of contaminants to drain properly 8 When operating the Feed Unit in conditions of high ambient air temperature or humidity the Feed unit must be equipped with auxiliary moisture separation and temperature reduction devices supplied by the end user Unless otherwise noted this manual covers equipment maintenance and operation for oponge Jet B VAC B VAC Pro and B VAC Pro 2 models oponge Jet B VAC User Manual 10 February 2005 Page 3 of 55 ooo oponge Jet B VAC User Manual 10 February 2005 2 0 Equipment Setup 2 1 Connecting 50 P Recycler 2 1 1 Connect Vacuum Hose from the Larg
38. otify the Operator or Maintenance Personnel For inspection the Pneumatic Media Classifier should be immediately switched off and all revolving parts should stop before any investigations are carried out Page 47 of 55 Sponge Jet B VAC User Manual 10 February 2005 7 0 Rebuild Maintenance 1 1 Replacement of Top Roller Bearing 10 11 Remove the Sieve Assembly Remove grease lines Remove ring 6 5 16 hex head cap screws top bearing housing cap and brass mole connector Remove top bearing housing with bearing Loosen the top bearing sleeve bolt Carefully press bearings and seal out of housing and top bearing sleeve Clean and deburr housing and sleeve examine parts for wear Press new bearing and seal into sieve and housing IMPORTANT Re pack bearing with grease See recommended lubricants Replace top bearing sleeve and sleeve bolt IMPORTANT Use thread locker on sleeve bolt Perma Lok MM115 or equal Insert top housing cap and 5 16 hex head cap screws Reattach grease lines 7 2 Replacement of Flywheel Bearing 1 2 3 10 11 Remove Sieve Assembly Release Side Cover clamp and open cover Loosen and remove top two 2 flexible rubber coupling locknuts 3 8 16 thread Remove three 3 5 8 11 hex nuts from Suspension Rods above rubber bushings Remove top sieve weldment Follow steps 1 through 6 of Replacement of Top Roller Bearing If not already complete Lo
39. ovement of media through the pressure vessel Figure G oponge Jet B VAC User Manual 10 February 2005 Page 35 of 55 Figure oponge Jet B VAC User Manual 10 February 2005 Figure Deadman Handle Trigger Assembly 1 Blast Hose The Blast Hose conveys the media from the Pressure Vessel to the Nozzle 2 Nozzle Connector The Nozzle Connector connects the Nozzle to the Blast Hose 3 Blast Nozzle The Blast Nozzle is an acceleration tip designed to focus the blasting media at a desired location for blasting activities 4 Twinline The Twinline flows the pneumatic circuit of air from the Deadman to the On Off Control Valve 5 Clean Out Screw depending on model The Clean Out Screw provides maintenance access to the internal components of the Deadman Handle 6 Deadman Handle The Deadman Handle allows for on or off operation of the Deadman System Page 36 of 55 Figure I Control Panel Inside View 1 T Handle Regulator The T Handle Regulator Controls the blast pressure and media feed pressure 2 Desiccant Filter The Filter removes vapor level moisture from the pneumatic Timer Circuit 3 Timers Timers are pneumatic timing mechanisms that regulate the delay interval of the Actuator s motion 4 Control Valve Air Motor The Agitation Control Valve provides the pneumatic signal that activates the Air Motor 5 Control Valve Actuator The Agitation Control Valve provides the pneumatic sign
40. picts the volume of air required to support three different nozzle sizes at 6 0 bar 90 psi The minimum compressor size recommendations below include a 50 reserve factor which is intended to account for the loss associated with friction and some nozzle wear Ahrasive Minimum Compressor Reg Nozzle Size Lb per Min Hr m CFM with Reserve 7 11mm 7 16 6 8 408 6 4m 225 10 6m 375 CFM 8 13mm 1 2 0 480 7m 250 10 6 12m 375 425 12 19 34 12 720 26 950 38 2 1300 CFM Remember the smallest in the entire system determines the maximum airflow volume for the entire blast system B Air Supply Hose requirements 1 32mm 1 25 1 0 hose up to 61m 200 2 51mm 2 1 0 hose up to 91m 300 3 2mm 3 1 0 hose above 91m 300 Use air lines larger than the recommended whenever possible C Fittings With 32mm 1 25 to 51mm 2 1 0 hose use 32 38mm 1 25 2 0 I D Universal 4 Lug Air Coupling With 51mm 2 and larger use Boss Fittings Sponge Jet B VAC User Manual 10 February 2005 Page 25 of 55 ooo Sponge Jet Feed Unit Requirements Continued d D Blast Hoses Sponge Media abrasive has been successfully blasted through 91m 300 of final Blast Hose However when choosing between long Air Supply Line and long Blast Hoses attempt to keep the Blast Hoses as short as practical Below are the recommended maximum lengths Upto 15m
41. pplies Feed Units with a single four 4 lug Chicago fitting on a 2 National Pipe Thread NPT nipple WARNING System is designed for a maximum 8 6 bar 125 psi Failure to install safety pins and proper restraints dog leash whip checks on the bull hose may result in personal injury securely attach the Sponge Jet Feed Unit s Port Hole Cover Fig 5 with the gasket in place Connect the Blast Hose Fig 1 and the Twinline Fig 4 Sponge Jet supplies blast hose connections with two 2 lug Universal fittings Check that the Main Air Ball Valve Fig B 8 is in the closed position and charge the supply line At the nozzle operator s command open the Main Air Ball Valve verify that a minimum of 7 bar 100 psi of inbound supply air registers on the Line Pressure Gauge Fig B 4 on the Control Panel Fig 1 Page 15 of 55 Operation amp Shutdown After the operator depresses the Deadman Handle Fig 6 allow the Feed continued Unit to pressurize This may take 5 to 10 seconds CAUTION Do not cycle the Deadman Handle while waiting for abrasive at the Nozzle as in conventional abrasive blasting Cycling the Deadman Handle will usually obstruct the Blast Nozzle and Blast Hose Once the Line Pressure Gauge Fig B 4 Blast Pressure Gauge Fig B 2 and the Media Feed Pressure Gauge Fig B 3 have stabilized in operation adjust the Blast Pressure Regulator Handle Fig B 5
42. r serves as protection for the components located inside the Lower Base Assembly Air Motor The Air Motor powers the Pneumatic Media Classifier Flywheel The vibratory energy generated directly by the Flywheel is transmitted to the Sieve Assembly Figure C 5 Suspension Rods The Sieve Assembly and the Vibratory Portion is isolated from the frame by the three suspension rods 6 Lower Base Assembly The Lower Base Assembly supports the Main Controls Air Motor Vibratory Portion and the Sieve Assembly 7 Vibratory Portion The Vibratory Portion is located over the Lower Base Assembly and Supports the Sieve Assembly Sponge Jet B VAC User Manual 10 February 2005 Page 52 of 55 Figure D Pan Clamps 1 Handle The lever Handle is used to secure the Pan Clamp to the Sieve Assembly 2 Threaded Rod The Steel Hook Top threads onto the Threaded Rod 3 Lock Nut The Lock Nut is used to prevent the Steel Hook Top from swiveling when dismounting the Pan Clamps 4 Steel Hook Top Adjustment for varying sized gaskets is made by turning the oteel Hook Top Figure D Sponge Jet B VAC User Manual 10 February 2005 Page 53 of 55 ooo EEE 6 0 Specifications Weight 450 Ib 136 kilo Gaskets One set 4 22 buna flat gaskets Clamps One set 4 double deck Pan Clamps with Lock Nuts Screens One 1 top 3 mesh 047 wire diameter 286 open area stainless
43. t Nozzle Fig H 3 from Blast Hose Fig H 1 and inspect for obstruction Remove obstructions as necessary 3 Disconnect all Blast Hose connections and inspect for obstructions Remove obstructions as necessary 4 Remove the Auger Tunnel End Cap Fig D 4 Check for media clog s Remove clogs if necessary Replace Auger Tunnel End Cap Sponge Jet B VAC User Manual 10 February 2005 Page 21 of 55 ooo Troubleshooting continued If an obstruction occurs in the Auger Tunnel End Cap area of Feed Unit rotate the Media Feed Pressure Regulator Handle Fig B 6 in a counter clockwise direction to the off position Clear the obstruction 6 Resume blasting Once a full stream of air without media is achieved slowly return the Media Feed Pressure Gauge Fig B 3 back up to the desired pressure by adjusting the Media Feed Pressure Regulator Handle in a clockwise direction 6 11 Air Flows through nozzle but with no media and auger is rotating Note After start up media flow is not instantaneous Even with only 50 of final Blast Hose initial media flow may require 15 seconds Stabilized media flow may require up to 4 minutes Conditions may change that period up or down 1 Check that Feed Unit contains an adequate amount of media Fill as necessary 2 While the Feed Unit is in operation check that the Agitation Indicator Eye Fig B 7 is blinking from green to black every few seconds while machine is pressurized and
44. the base of the Suspension Rods and the lower compressed rubber bushings After adjustment is made these nuts must be securely tightened At the same time check to be sure the faces of the flanges remain parallel 5 4 Alignment of Flanges A minimum clearance of 1 14 32 mm must be maintained between the faces of the Coupling Flanges The Coupling Flanges must be held parallel to within 010 Parallel alignment of the flange is performed by adjusting the three 3 lower Suspension Rod nuts After the coupling flanges are proven to be parallel installation of the flexible rubber coupling may proceed NOTE The flexible rubber coupling is 1 24 5 mm thick with four 4 1 8 3 2 mm thick bosses WARNING Never run the motor with only the flexible rubber coupling attached to the motor flange Failure to observe this precaution may result in serious damage and or injury 5 5 Sieve Assembly The dismountable Sieve Assembly Fig A is constructed of stainless steel When it is correctly assembled and fastened the rim weldments should be durable Failure to properly assemble and fasten the Sieve Assembly will Sharply shorten the life of the weldments The Sieve Assembly consists of five parts Assemble as follows 1 Place the Fine Particle Downspout Fig A 7 through the hole provided in the Vibratory Portion Fig C 7 Note Be sure the downspout is centered 2 Place a Flat Gasket Fig A 4 into the Shallow Funnel
45. 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 1 1 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 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 B VAC User Manual 10 February 2005 Page 29 of 55 ooo eee Figures oponge Jet 400HP Feed Unit Figures taken from 400HP Manual Figure 1 Hopper Lid Not applicable for B VAC
46. weight lubricating oil as necessary then replace the Auger Chain Guard e Lubricate each Stationary and Swivel Caster Wheel with multi purpose grease as needed e Inspect all pneumatic component supply lines for wear damage and connection security Page 18 of 55 ooo 6 0 Troubleshooting Inevitably circumstances arise that can adversely effect the performance of the equipment The following section will guide a trained operator in the proper diagnosis of equipment operating problems It is strongly recommended these procedures be retained with each Feed Unit as a reference guide Sponge Jet Inc Technicians are available 24 hours a day 365 days a year by calling the U S A 800 SPONGEJET 800 776 6435 or 603 431 6435 6 1 Feed Unit will not run 1 Confirm the Main Air Ball Valve Fig B 8 is open 2 Confirm the Emergency Stop Button Fig B 1 is not pushed in 3 Confirm the Twinline Fig 4 connections at the Feed Unit and at the Deadman Handle Fig 6 handle are secure 4 Check for holes or other damage in the full length of the Twinline and repair as necessary 5 Check that the Line Pressure Gauge Fig B 4 registers adequate pressure If necessary turn on or charge the compressor 6 Test Feed Unit for proper operation if this did not solve the problem proceed to Step 6 2 otherwise resume blasting 6 2 Check Deadman Trigger Handle 1 Depress and then release the Deadman Handle Fig
47. weight to the shaft by a squeeze fit This weight is set by the factory at zero degrees with flywheel weights To achieve maximum amplitude loosen with a 5 16 Allen wrench and rotate the weight 180 degrees and tighten Settings between 0 degrees and 180 degrees may achieve best production for different products NOTE The amplitude setting of the Pneumatic Media Classifier with the flywheel shaft running at 3450RPM should not exceed flywheel setting 73 which is factory set Adjustment requires the use of a RPM calibration tool WARNING Failure to use a calibration tool or properly set the RPM rate can damage the equipment and will void the warranty Page 44 of 55 ooo 5 3 Alignment Prior to shipment this Pneumatic Media Classifier has been adjusted for efficient operation Under normal operating conditions these settings should not need attention However shocks can occur during shipment which may necessitate some slight re alignment Efficient operation results when the motor and the flywheel shaft are parallel When this occurs the faces of the flywheel Upper Coupling Flange and the motor flange are also parallel If uneven vibrating or jerking occurs determine that the coupling faces are parallel by measurement If they are not parallel adjust by varying the length of the three 3 Suspension Rods Fig C 5 This operation is performed by loosening and screwing up or down the three 3 pairs of hexagon nuts secure

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