Clemco Zero Pulsar Plus 55-S, Manual

Page 1: ...useful life of these products All estimates regarding production rates or finishes are the responsibility of the user and must be derived solely from the user s experience and expertise not from information contained in this material It is possible that the products described in this material may be combined with other products by the user for purposes determined solely by the user No representati...

Page 2: ...oderate injury Warning indicates a hazardous situation that if not avoided could result in death or serious injury Danger indicates a hazardous situation that if not avoided will result in death or serious injury 1 3 Table of Contents SUBJECT SECTION LOCATION INTRODUCTION 1 0 Scope of Manual 1 1 Safety Alerts 1 2 Table of Contents 1 3 General Description 1 4 Theory of Operation 1 5 Control Console...

Page 3: ... media from nozzle 8 9 Blowback through media hose 8 10 Blasting does not begin when foot pedal is pressed 8 11 Blasting continues after releasing foot pedal 8 12 Media buildup in cabinet hopper 8 13 Static shocks 8 14 Dust or media leaking from cabinet 8 15 Dust leaking from dust collector 8 16 Dust collector does not pulse 8 17 Dust collector pulse is steady stream of air instead of quick pulse ...

Page 4: ...e After striking the object being blasted blast media fines dust and byproducts generated by blasting fall through the grate into the cabinet hopper These particles are then drawn into the power module reclaimer for separation When the foot pedal is released blasting stops Plus Pulsar Figure 1 Refer to Section 2 0 for setup instructions and additional components Refer to Figure 2 of additional cab...

Page 5: ...ge Green Pushbutton START Switch Blast Pressure Gauge Blast Pressure Pilot Regulator Red Pushbutton STOP Switch BNP Blast Gun Glove Ports Control Tubing From Power Module as shown in Figure 3 Male Power Cord Connector Power Cord From Power Module as shown in Figure 3 Backside of the Control Console Flex Hose To Power Module as shown in Figure 3 Blow Off Hose as shown in Figure 3 Media Hose as show...

Page 6: ... 2 Differential Pressure White Differential Pressure Green Air In Blue Air Out Gray Air Hose BNP Gun refer to Figure 2 Exhaust outlet Damper Exhauster Motor Filter Cartridge Dustbin Shown removed from under dust collector Blow Off Hose refer to Figure 2 Media Hose refer to Figure 2 Access Door Dust Collector Dustbin Interlock Switch Media Metering Valve 120 Volt U Ground Plug Pneumatic Inlet Assem...

Page 7: ...button Switch The button lights up when power is applied to the cabinet The pushbutton does not light if the dustbin interlock is not engaged Pushing in the button turns on the cabinet light and starts the exhauster Other controls will not operate unless the exhauster is running 3 Red Stop Pushbutton Switch Pushing in the button stops the exhauster and all other controls 4 Blast Pressure Gauge Dis...

Page 8: ...nets The media sizes shown in this section are provided as a guideline only The guideline is based on standard 5 32 orifice air jet with 5 16 nozzle and average conditions with variables such as blast pressure media air mixture visibility inside the cabinet humidity and reclaimer cleaning rate Several variables affecting the reclaimer cleaning rate include reclaimer size cfm contamination of parts...

Page 9: ...n Figure 5 1 11 2 The compressed air filter at the power module s air inlet connection removes condensed water from the compressed air Its use is especially important in areas of high humidity or when fine mesh media are used Moisture causes media to clump and inhibits free flow through the feed assembly If the filter does not remove enough moisture to keep media dry and flowing it may be necessar...

Page 10: ...the power module 2 4 Connect Electrical Service Shorting electrical components can result in serious injury or death from electrical shock or equipment damage Electrical power must be locked out and tagged out before performing any electrical work All electrical work or any work done inside a control panel or junction box must be performed by a qualified electrician and comply with applicable code...

Page 11: ...t 3 2 Cabinet Curtains Installation 3 2 1 Match curtains to corresponding wall and doors 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...

Page 12: ...ecessary for precise media separation as the reclaimer s efficiency is achieved by a centrifugal balance of air flow particle weight and size Reclaimer static pressure is set by adjusting the dust collector exhaust damper refer to Section 5 4 to adjust static pressure Refer to Section 5 10 for using the manometer to set reclaimer static pressure 3 5 HEPA Afterfilter 3 5 1 Installation and operatin...

Page 13: ... until the air from the gun and the cabinet are clear Turn OFF the exhauster and replace the plug 4 4 Loading and Unloading Parts 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...

Page 14: ...ely Shut down the cabinet immediately if dust discharges from the dust collector or cabinet Check to make sure the dust collector filter cartridge is correctly seated and that it is not worn or otherwise damaged Prolonged breathing of any dust can result in serious lung disease Short term ingestion of toxic dust such as lead or heavy metals poses an immediate danger to health Toxicity and health r...

Page 15: ...pulling it out as shown in Figure 13 and turn it clockwise to increase pressure or counterclockwise to decrease pressure Pressure may drop slightly from closed line pressure when blasting starts Once operating pressure is set push the knob to lock it and maintain the setting 5 2 Air Jet Figure 14 5 2 1 Thread the air jet 4 1 2 to 5 full turns into the gun body Doing so leaves 3 1 2 to 4 threads ex...

Page 16: ...usting and monitoring static pressure The manometer kit and differential pressure gauge are listed in Section 10 1 Optional Accessories Refer to Section 5 10 for using the manometer to set reclaimer static pressure The following are static pressure starting points for given media Static pressure may need to be lower with finer media higher with coarser media If a manometer is not available begin w...

Page 17: ...djusting screw nuts 5 6 6 Test the operation with the doors open and then again closed Negative pressure inside the cabinet may cause the doors to flex inward Tests should be performed with the exhauster running Point the nozzle away from the door during the tests and open the door only enough to disengage the interlock switch The interlocks should stop the blasting when either door is open and pe...

Page 18: ...s pulled up disengages it as shown in Figure 19 Turn the knob clockwise to increase pressure or counterclockwise to decrease pressure Once operating pressure is set push down on the knob to secure it and maintain the setting Figure 19 NOTE The blue insert on the adjustment knob locks and unlocks the knob which prevents unintentional adjusting While the knob is down in the lock position slide the i...

Page 19: ...r subranges If the timer function is accidentally changed refer to Section 5 9 4 to reset it to Function A If timer subranges are accidentally changed refer to Section 5 9 5 to reset them to factory settings 5 9 1 1 The LED display comes on when the green start pushbutton is pressed and power is supplied to the timer TEST o f f o n on TEST o f f o n on FACTORY SETTINGS Figure 22 5 9 1 2 The timer ...

Page 20: ...f ON time is accidentally changed reset it to 150 milliseconds as follows NOTE The numbers shown in Figure 24 signify the following step numbers 1 Make sure the ON subrange is set to milliseconds as noted in Section 5 9 5 2 Figure 26 2 Press the right on arrow up button and ON appears briefly on the display 3 If the number on the display is above 15 decrease time by pressing the left off arrow dow...

Page 21: ...seconds x 10 For example if the seconds subrange light is lit press the off arrow down button past 0 seconds to lower the subrange to milliseconds 3 Set ON time to 15 15 milliseconds x 10 150 milliseconds per Section 5 9 3 TEST o f f o n on FACTORY SETTING FOR ON SUBRANGE Figure 26 5 10 Using the Optional Manometer to Set Reclaimer Static Pressure NOTE These instructions and the illustrations in F...

Page 22: ...net doors and turn the exhauster ON The negative static pressure moves fluid in the tube NOTE Readings must be taken with the cabinet doors open and with the exhauster running Figure 28 5 10 8 2 To find the static pressure add the number of inches the fluid travels up one column to the inches the fluid travels down the other column Refer to the example in Figure 28 To take occasional readings refe...

Page 23: ...vered in this section Adjust the inspection schedule as needed based on the following Usage Frequently used cabinets require more maintenance and inspections than those occasionally used Type of media Aggressive media wears parts faster than nonaggressive media Condition of parts being blasted Heavily contaminated parts require more maintenance to the cabinet s media recovery system Friability of ...

Page 24: ...tes a leaking or damaged filter cartridge Check immediately Note that a small amount of dust egress is normal for a short time before a new cartridge is seasoned 6 3 3 Drain pulse reservoir Figure 30 At the end of the day open the petcock to drain water from the reservoir and bleed air from the supply line Close the petcock when the line is bled Figure 30 6 4 Weekly Inspection and Maintenance Befo...

Page 25: ...m other heavy metals and corrosives can cause serious injury or death Identify all material that is being removed by blasting and obtain a Safety Data Sheet SDS for the blast media Waste dust in the collector can cause serious injury or death through inhalation absorption or ingestion The employer shall meet all OSHA requirements including but not limited to those for confined space combustible du...

Page 26: ...lenses prolongs the life of the view window 7 4 2 The best way to install a cover lens is to remove the window from the cabinet If for some reason it is not practical to remove the window the lens may be applied with the window glass in place 7 4 3 To install a cover lens carefully remove the adhesive backing making sure the adhesive remains on the lens and apply the lens to the clean dry inner su...

Page 27: ...ional backing as needed and work the strip around the radius of each corner pressing it firmly to bond Trim the gasket to fit and compress the ends to seal Figure 34 7 6 5 Using 5 32 thick strip gasket repeat the process on the underside of the window frame 7 6 6 Trim around the window frame bolt slots as needed 7 7 Window Frame Removal Figure 35 7 7 1 Remove the two window frame nuts located on t...

Page 28: ...urface of the cabinet 7 8 3 3 Lay a length of strip gasket along a long edge of the light opening and cut to length allowing 3 4 overlap on each end Peel the adhesive backing and adhere the strip gasket to the edge of the opening as shown in Figure 36 Press the gasket to bond the adhesive to the cabinet Repeat the process on the remaining sides compressing the ends to seal 7 8 4 LED light assembly...

Page 29: ...upply bleed the supply line and perform lockout and tagout procedure to the air supply line Failure to do so can cause injury from the release of trapped compressed air 7 10 1 To service or replace any module in the pneumatic inlet assembly the mounting clips that attaches it to the part next to it must be loosened or removed Use a TORX T20 screwdriver to loosen the mounting screws enough to remov...

Page 30: ...the new wear plate from seating against the reclaimer wall and top 7 11 4 Angle the new wear plate into the reclaimer inlet and position it so the straight end is flush with the inlet Use locking pliers clamps or other means to hold the wear plate in position making sure the leading edge of the wear plate is aligned with the reclaimer inlet and that the top edge is even with the top of the reclaim...

Page 31: ...sh bag over the cartridge to contain dust 7 12 5 Rotate the cartridge to the right to remove the lug slots from the rear shoulder screws and tensioning knob and then remove the cartridge from the dust collector access door Figure 42 7 12 6 Tie off or otherwise seal the top of the bag and dispose of the sealed bag in a suitable disposal receptacle NOTE Blasting media is usually nontoxic however som...

Page 32: ...ower toggle switch to ON to start the exhauster and pulse cycle 7 14 Clean Dust Collector s Inline Filter Figure 43 7 14 1 To avoid cartridge pulsing during cleaning make sure power is OFF red pushbutton is pressed Refer to the matching step numbers in Figure 43 and clean the filter as follows 1 Remove the filter and tubing from the lower snubber by pushing in on the snubber s retaining collar and...

Page 33: ...re 44 Figure 44 7 16 2 Remove the four cover screws and remove the cover while keeping the diaphragm in place within the body NOTE Before removing the diaphragm and O ring note the round dimple on the upper left on the valve body and the position of the triangular shape on the upper left of the diaphragm as shown in Figure 45 When reinstalling the diaphragm the marks must be aligned as shown Figur...

Page 34: ...worn in flex hose between cabinet hopper and reclaimer inlet or reclaimer outlet and dust collector inlet Replace hose 8 1 9 Obstruction in flex hose between the cabinet hopper and reclaimer inlet Inspect hose for blockage 8 1 10 Paddle wheel worn Check wheel for wear 8 1 11 Pulse pressure set too low Refer to Section 5 8 to adjust pulse pressure 8 1 12 Pulse OFF time needs to be decreased Refer t...

Page 35: ...e air especially fine mesh media in areas of high humidity Empty the media and store it in an airtight container when the cabinet is not in use 8 5 5 A vibrator mounted on the reclaimer mounting bolt may help prevent bridging of fine mesh media NOTE To avoid the possibility of compacting media a vibrator should be set up to start when the foot pedal is pressed and to stop when the pedal is release...

Page 36: ... to reclaimer NOTE Do not pour media directly into the cabinet hopper as overfilling may occur Overfilling results in media carryover to the dust collector and possible blockage in the conveying hose 8 13 1 Exhauster motor rotating backward The motor should rotate as indicated by the arrow on the exhauster housing If it does not rotate in the proper direction lockout and tagout electrical power an...

Page 37: ...itch is pressed 2 Make sure the power cord is connected and that power is supplied to the outlet 3 If the display is not lit after checking the above have the electrical system checked by a qualified electrician Observe the LED display If the display counts down OFF time to 0 the diaphragm pulse valve is malfunctioning Inspect the pulse valve s diaphragm and O ring for damage 8 17 3 Check the puls...

Page 38: ...in switch is bad 9 1 4 1 With the dust collector bin locked in place correctly check voltage between Terminals 10 and 2 If 120 VAC is not present dust collector bin switch has an issue Check wiring and mechanical engagement per Section 5 7 9 1 5 Green pushbutton light is faulty 9 1 5 1 Replace either the LED light inside the green pushbutton or the entire pushbutton light assembly 9 2 Dust collect...

Page 39: ...and pedal 9 5 Blast solenoid valve not working 9 5 1 With the dust collector on both doors closed and the foot pedal pressed voltage should be on Terminals 5 and 2 and with the blast solenoid valve should actuate ON Using a metal screwdriver place the stem on top of the valve where the screw is located that attaches the cable to the valve a light magnetic feel should result as the screwdriver is s...

Page 40: ...cks for both doors 30873 Lock pins pkg of 25 for twist on hose couplings 11203 Safety cable for 1 2 to 1 1 4 OD hose 15012 Anti fatigue floor mat 2 ft x 3 ft for front of cab 24744 Window cover lens pack of 5 06190 Differential pressure gauge assembly for measuring reclaimer static pressure 23355 Optional Extension Nozzles Figure 48 Item Description Stock No 1 3 Straight extension nozzle No 5 5 16...

Page 41: ... 4 ID 11798 10 Adaptor pipe universal for 4 flex hose 23295 11 Gasket 4 adaptor pipe 23258 12 Bracket door interlock actuator 19152 13 Detent sleeve door interlock 15042 14 Switch door interlock 30299 15 Cover interlock switch 30201 16 Shelf adjustable foot 27599 17 Pin 1 2 X 2 quick release each 24838 18 Bracket foot shelf mounting each 27600 19 Gasket 5 32 x 3 4 3 ft required 00192 20 Gasket hop...

Page 42: ... Fitting push lock el 1 8 x 1 4 tube 30371 9 Adaptor push lock el 1 4 x 1 4 tube 30373 10 Reducing union 1 4 x 5 16 tubing 30372 11 Panel nut pressure regulator mount 30374 12 Switch green LED pushbutton 30291 13 Switch red pushbutton 30292 14 Washer color code White differential pressure IN 30417 Blue air IN 30418 Green differential pressure OUT 30419 Gray air OUT 30420 15 Tubing 5 16 OD black sp...

Page 43: ...valve 12011 Figure 52 10 6 Gloves and Glove Mounts Figure 53 Item Description Stock No A Armrest glove mount kit each includes items 1 thru 5 10 and 11 30192 B Mounting ring kit glove mount includes items 2 thru 5 10 and 11 30499 C Glove and armrest mount kit right hand includes items 1 8 standard and 9 30580 D Glove and armrest mount kit left hand includes items 1 7 standard and 9 30581 1 Armrest...

Page 44: ...14 Urethane covered 11574 2 O ring 08975 3 Gun body 11802 4 Lock nut air jet 11913 5 Elastic jet sleeve 12097 6 Air jet assembly w Item 5 No 4 12342 No 5 12343 No 6 12344 7 Fitting hose 3 8 NPT x 1 2 barb 06369 8 Hose end 1 2 barb x 1 2 fem swivel 15002 9 Nozzle ceramic No 5 green tip 11930 No 6 blue tip 11931 Nozzle boron carbide No 5 11935 No 6 11936 Nozzle tungsten carbide No 5 13118 10 Hose 1 ...

Page 45: ...18 Hose end 1 2 barb x 3 8 male NPT 06369 19 Blow off nozzle 13116 20 Air hose 1 2 ID specify feet required 12472 21 Gun assembly BNP No 5 standard Refer to Section 10 8 for other sizes 12302 22 Hose media 1 2 ID clear urethane specify feet required 10 ft standard 12476 23 Metering valve assembly 12417 24 Fitting str 3 8 male NPT x 3 8 tube 30439 25 Fitting str 3 8 male NPT x 1 4 tube 30438 26 Fit...

Page 46: ...30180 2 Gasket 4 inlet pipe adaptor 11746 3 Gasket door 5 16 x 1 2 3 ft required 30449 4 Debris screen 8 mesh 21265 5 Liner reclaimer door 30448 6 Clamp assembly reclaimer door 30189 7 Metering valve 12417 8 Door assembly reclaimer includes items 3 5 and hinge 30459 9 Wear plate w mounting screws 14060 10 Clamp 6 hose 00750 11 Hose 6 unlined flex 4 ft required 12452 12 Clamp 4 hose 11577 13 Hose 4...

Page 47: ... 4 brass st 02027 15 Nipple 1 4 brass hex 02808 16 Gasket exhaust damper 300 cfm 30198 17 Clamp J hook dustbin 30190 18 Knob dust door retainer 30191 19 Clamp 6 hose 00750 20 Hose 6 unlined flex 4 ft required 12452 21 Switch interlock limit 30299 22 Cover interlock switch 30201 23 Filter inline 1 4 tube 23415 24 Bushing 1 4 NPT x 1 8 NPT brass 02010 25 Fitting snubber el 1 8 NPT x 1 4 tube 30455 2...