Caviblaster 2828-E Operation & Maintenance Manual Download Page 3

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TABLE OF CONTENTS

1.0 UNIT SPECIFICATIONS.............................................................................................5
2.0 GENERAL DESCRIPTION..........................................................................................6

2.1 Using this manual.....................................................................................................7
2.2 Conventions.............................................................................................................7
2.3 Scope.......................................................................................................................8
2.4 Terms and Abbreviations.........................................................................................8

3.0 SAFETY INFORMATION............................................................................................9

3.1 Personal Safety........................................................................................................9
3.2 Personal Protective Equipment..............................................................................10
3.3 Modification to the Equipment................................................................................11

4.0 INSTALLATION.........................................................................................................12

5.0 OPERATION..............................................................................................................19

6.0 MAINTENANCE........................................................................................................27

6.1 Basic Preventive Maintenance Recommendations...............................................28
6.2 Pump Service.........................................................................................................29
6.3 Inspection/Cleaning of Water Inlet Strainer...........................................................29
6.4 Inspection / Maintenance of the Zero-Thrust Gun.................................................31

7.0 WINTERIZATION......................................................................................................32
8.0 TROUBLESHOOTING..............................................................................................33
9.0 REPLACEMENT PARTS..........................................................................................35

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For more information please email [email protected] or call 1-(352)275-5319

Summary of Contents for 2828-E

Page 1: ...CAVIDYNE LLC 5077 Fruitville Rd Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 Operation Maintenance Manual Model 2828 E ...

Page 2: ...ly Serious personal injury or death may result from improper use Commercial Diver s gear should be used to operate the CaviBlaster system Electric shock can cause severe burns or death Ground system before connecting power supply Use dedicated circuit installed by a licensed electrician Circuit should supply adequate voltage and amperage under load CAUTION DO NOT USE THIS EQUIPMENT TO CLEAN SENSIT...

Page 3: ...m 15 4 3 3 Three water supply conditions are acceptable for the CaviBlaster power unit 15 5 0 OPERATION 19 5 1 Preparing the CaviBlaster for Operation 19 5 2 Startup of the CaviBlaster 19 5 3 Normal Operation 21 5 4 Adjusting the CaviBlaster for Maximum Performance 22 5 5 Recommendations for Effective Results 24 6 0 MAINTENANCE 27 6 1 Basic Preventive Maintenance Recommendations 28 6 2 Pump Servic...

Page 4: ...Figure 4 2 Installation Guidelines 13 Figure 4 3 Gravity Feeding Source 16 Figure 5 1 Engine Emergency Shut Down and Throttle Control 20 Figure 5 2 ZT Gun Pressure Calibration 23 Figure 5 3 Gun Position for Best Results 25 Figure 6 1 Inspection Cleaning Water Strainer Filter 30 Figure 6 2 Zero Thrust Gun 31 Page 4 35 For more information please email sales cavidyne com or call 1 352 275 5319 ...

Page 5: ...allation Environment Indoor or Outdoor See Section 4 for installation requirements Water Inlet Pressure Limits 0 PSI Atmospheric Pressure to 50 PSI Maximum 0 BAR to 3 5 BAR See Section 4 for further requirements Overall Unit Dimensions L x W x H 63 x 47 x 50 166 cm x 119 cm x 127 cm Maximum Pressure Hose Length 600 LF 200 meters of 3 4 diameter Power Unit Weight Dry 2 550 LBS 1160 KG Zero Thrust G...

Page 6: ...thrust gun uses a trigger operated valve to control the water stream off and on If the valve is closed the power unit goes into bypass mode unloading the engine and the pump The CaviBlaster 2828 E60 power unit is a complete plug and play system built into a self supporting frame that allows quick deployment and or installation of the unit Water can be supplied from either a pressurized source dire...

Page 7: ...rom CAVIDYNE or other personnel familiar with the operation of this equipment 2 2 Conventions The first time a component is mentioned it is typically followed by a figure reference e g Emergency Stop button See Figure 2 1 Figure numbers and section numbers are always coincident When other sections are referenced the SECTION NAME will appear in italic caps The electronic version allows users to cli...

Page 8: ... and pump are covered by the manufacturer s literature found in the Appendix 2 4 Terms and Abbreviations CCW Counterclockwise CW Clockwise EOS End of Section GPM Gallons Per Minute HP Horsepower LPM Liters Per Minute PPE Personal Protective Equipment PSI Pounds Per Square Inch without suffix assumed to be gauge pressure Z T Gun Zero Thrust Gun HPP High Pressure Pump Page 8 35 For more information ...

Page 9: ...r to the applicable section in this manual for the correct procedures prior to any installation setup or maintenance work 3 1 Personal Safety Operation of the CaviBlaster 2828 E60 underwater cleaning system must only be attempted by commercial divers or other personnel who have been trained in its use Appropriate protective equipment should always be worn Operation of the system without the proper...

Page 10: ... recommended CAVIDYNE suggest wearing vented earplugs such as Doc s Proplugs for diver hearing protection The operators of the CaviBlaster system should always wear neoprene or heavy rubber gloves to provide protection to the hands and in particular to the nails The gloves will absorb most of the energy produced by bursting cavitation bubbles and prevent the cavitation bubbles from contacting the ...

Page 11: ...ns will void the equipment warranty Unauthorized modification or part substitution can result in serious personal injury or property damage This space intentionally left blank Page 11 35 For more information please email sales cavidyne com or call 1 352 275 5319 EOS Unauthorized replacement of any part may lead to catastrophic equipment failure and serious personal injury Use of guns or pressure n...

Page 12: ...lled immediately provide adequate indoor storage to protect against damage If there are missing parts spare parts contact freight carrier or insurance company The CaviBlaster power unit should be lifted from underneath the frame using the forklift channels or by using the lifting eyes provided on top of the frame Verify that lifting equipment is rated for the weight listed in Section 1 0 UNIT SPEC...

Page 13: ... cooling air flow See Figure 4 2 below Installation location must be a level surface able to safely support the unit weight listed in Section 1 0 UNIT SPECIFICATIONS Orient unit to allow unrestricted access to the hose connection plate and control panel located on the front of the unit Allow a minimum of three feet behind the unit and access from above to conduct service and repair work Take note ...

Page 14: ... 8 Close and lock the control panel door 9 Connect the feed or suction hose See Section 4 3 2 10 Connect the bypass hose See Figure 2 2 11 Connect the pressure hose See Figure 2 2 4 3 1 Connecting the Water Source The CaviBlaster power unit can be used with seawater or fresh water Note the unit must be flushed with fresh water for 1 2 minutes after each use in seawater to ensure long service life ...

Page 15: ...ming The feed pump should be charged with water to more effectively draw from the source It is suggested a positive pressure water source be utilized to initially charge the feed pump system Note The feed pump may require upwards of 5 to 7 minutes to draw sufficient water to prime the system before starting the main pump system Once fully primed should a restart be needed confirm priming is comple...

Page 16: ... Figure 2 2 Connect the cam lock socket on the 1 1 2 clear PVC feed hose to the water inlet connection on the control panel See Figure 2 2 Place the other end of the hose in the water supply THE PUMP SYSTEM MUST BE FULLY PRIMED BEFORE STARTING THE HPP PUMP OR SERIOUS DAMAGE TO HPP PUMP WILL OCCUR REFER TO SECTION 4 3 2 ABOVE FOR PRIMING INSTRUCTIONS Page 16 35 For more information please email sal...

Page 17: ...meter to the water inlet 1 1 2 cam lock plug Connect the other end of the hose to the water supply tank outlet Open any valves installed in the water supply line Make sure the lowest point in the hose line is the connection with the power unit THE PUMP SYSTEM MUST BE FULLY PRIMED BEFORE STARTING THE HPP PUMP OR SERIOUS DAMAGE TO HPP PUMP WILL OCCUR REFER TO SECTION 4 3 2 ABOVE FOR PRIMING INSTRUCT...

Page 18: ...mail sales cavidyne com or call 1 352 275 5319 Ensure that the feed hose is connected to the inlet connection and the water supply is on prior to starting the pressure pump Failure to supply water to the pressure pump will cause damage to the pump ...

Page 19: ...un for any signs of damage 2 Check that the motor is clean and ventilation openings are clear 3 Inspect the inline strainer and filter media to ensure that neither are clogged See Figure 6 1 Clean or replace as necessary 4 Check for proper pressure pump oil level See pump Owner s Manual found in the Appendix Add oil SAE 30 non detergent if necessary 5 2 Startup of the CaviBlaster Before starting t...

Page 20: ...perations ensure that the system is properly and fully primed and the diver gun is submerged in water If the diver is not wearing a helmet hearing protection is recommended CAVIDYNE suggests vented earplugs such as Doc s Proplugs for diver hearing protection 8 Wear neoprene or rubber gloves to protect the hands and follow all safety regulations that may be applicable to the work being performed 9 ...

Page 21: ...o bypass 3 If the diver operating the unit must be replaced or the cleaning operation must be interrupted or terminated turn the unit off and then release the water pressure in the hose s by squeezing the gun trigger to the open or ON position See Figure 5 3 while under water Revert back to step 5 2 of the operating instructions when the diver or replacement is ready to continue cleaning Although ...

Page 22: ...gun because of the danger of the operator coming in contact with either of the water streams from the cavitating or zero thrust nozzles Cavidyne does NOT recommend calibrating the gun out of the water Use extra care to avoid both water streams if doing so Ensure that both the cavitation and zero thrust nozzles are pointed away from the diver s or operator s hands arms and body Start the power unit...

Page 23: ... gun Pressure Calibration Page 23 35 For more information please email sales cavidyne com or call 1 352 275 5319 Hoses are rated for 3 000 psi 205bar Pressures above 3 000 psi 205bar could result in pump and or hose failure ...

Page 24: ...25 to 45 degree angle to the surface being cleaned See Figure 5 3 The diver needs to observe the shape of the cavitating jet cone At greater depths the higher ambient pressure will cause the jet cone to be shorter The widest zone of the cone is the most efficient part of the cavitating jet Placing the nozzle closer than 2 inches 5 cm from the surface being cleaned will not allow for efficient cavi...

Page 25: ...This space intentionally left blank Page 25 35 For more information please email sales cavidyne com or call 1 352 275 5319 ...

Page 26: ...n the main switch to the OFF position 4 Push in the E Stop button 5 Squeeze the gun trigger to the open or ON position See Figure 5 3 to release the water pressure remaining in the hose s while the gun is submerged 6 It is now safe to remove the gun from the water 7 Flush the system and rinse the power unit with fresh water at the end of the day if the system has been used with seawater This space...

Page 27: ... or approved by CAVIDYNE Use of any other parts may lead to equipment failure and severe personal injury CaviBlaster must be flushed and rinsed with fresh water after each use in sea water Failure to flush and rinse the unit will result in premature wear and tear on the components and decreased service life Failure to flush and rinse the unit can cause the pump valve s to stick in the open positio...

Page 28: ...est X Replace pump oil 3 X Check pump valves and seals for wear change if necessary X Lubricate motor bearings with high grade ball or roller bearing grease X Whichever occurs first 1 If any hose damage is found replace hose immediately 2 Remove gun from water with system at operating pressure and trigger in the closed or OFF position If water is leaking out of barrel or handle the gun trigger val...

Page 29: ...e main power switch OFF and isolate or disconnect the water source from the inlet connection to the power unit 2 Unscrew the strainer bowl from the housing turn CCW See Figure 6 1 3 Pull the bowl down and remove the filter strainer 4 Inspect the filter strainer and flush any debris clean with clean water 5 Push filter strainer back into housing and push the bowl back onto filter housing 6 Thread t...

Page 30: ...Figure 6 1 Inspection Cleaning Water Filter Strainer Page 30 35 For more information please email sales cavidyne com or call 1 352 275 5319 ...

Page 31: ...bmerged 3 If the gun will not be used for a period of several days flush the gun as noted remove the whip hose from the super swivel With the gun turned upside down pour approx 5ml of lubricating oil into the water inlet of the gun while opening and closing the trigger to allow oil to reach the positioning pin and valve cone This will minimize the possibility of corrosion or mineral crystals from ...

Page 32: ...freeze solution 3 Attach a minimal amount of pressure hose to the pressure connection on the control panel See Figure 2 2 and direct the open outlet of the hose into the antifreeze tank 4 Attach a minimum amount of hose to the start up by pass valve and place the open end into the antifreeze tank 5 Open the start up by pass valve and start the unit and make sure the pump is primed 6 Close the star...

Page 33: ... be approximately equal to isolate and correct the problem Rotor rubbing on stator Check air gap clearance and bearings Tighten thru bolts Over voltage or under voltage check input voltage at each phase Open stator winding check stator balance at all phases for balance Grounded winding perform dielectric test and repair Improper connections inspect all connections for proper termination clearance ...

Page 34: ...orce water past the seals and damage the seals and starving the pressure pump of water can overheat and damage the seals Check the plungers for cracks Check the plunger rod O ring for damage 9 AFTER RELEASING THE MECHANICAL TRIGGER WATER IS STILL LEAKING OUT OF THE GUN Replace the mechanical trigger valve assembly in the gun handle 10 ZERO THRUST GUN IS NOT CLEANING PROPERLY Verify that the system...

Page 35: ...alve kit 04 KIT UD 142 1 1 Pump brass kit 04 KIT UD 140 1 1 Pump plunger rod O ring kit 04 KIT UD 141 1 1 Pressure regulating unloader repair kit UB 1 1 Trigger valve repair kit small gun 202700490 1 1 Trigger valve repair kit large gun 203300490 All parts can be ordered from CAVIDYNE LLC 5077 Fruitville Rd Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 www cavidyne com EOS Page 35 35 For more...

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