CAVIDYNE CAVIBLASTER 2040-ROV Operation & Maintenance Manual Download Page 3

Page: 3 / 26



5077 Fruitville Rd.; Ste 109-157



Sarasota, FL 34234 U.S.A.



Phone 352.275 5319

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TABLE OF CONTENTS

1.0 UNIT SPECIFICATIONS ................................................................................................5

2.0 GENERAL DESCRIPTION ............................................................................................6

2.1 Using this Manual .......................................................................................................8

2.2 Conventions ................................................................................................................8

2.3 Scope .........................................................................................................................8

2.4 Terms and Abbreviations ............................................................................................8

3.0 SAFETY INFORMATION ............................................................................................. 10

3.1 Personal Safety ........................................................................................................ 10

3.2 Personal Protective Equipment................................................................................. 11

3.3 Modification to the Equipment................................................................................... 12

4. 0 INSTALLATION .......................................................................................................... 13

4.1 Uncrating and Lifting ................................................................................................. 13

4.3 Initial Set-Up ............................................................................................................. 14

5.0 OPERATION ................................................................................................................ 15

5.1 Preparing the CaviBlaster

for Operation ................................................................. 15

5.2 Startup of the CaviBlaster

...................................................................................... 15

5.3 Normal Operation ..................................................................................................... 16

5.4 Adjusting the CaviBlaster

for Maximum Performance ............................................ 17

5.5 Recommendations for Effective Results ................................................................... 19

6.0 MAINTENANCE ........................................................................................................... 22

6.1 Basic Preventive Maintenance Recommendations ................................................... 23

6.3 Pump Service ........................................................................................................... 23

6.4 Inspection/Cleaning of Water Inlet Strainer .............................................................. 23

8.0 TROUBLESHOOTING ................................................................................................. 24

9.0 REPLACEMENT PARTS ............................................................................................. 25

APPENDIX - COMPONENT LITERATURE ....................................................................... 26

Summary of Contents for CAVIBLASTER 2040-ROV

Page 1: ...CAVIDYNE TM LLC 5077 Fruitville Rd Ste 109 157 Sarasota FL 34232 Phone 352 275 5319 www caviblaster com Model 2040 ROV Version 1 0 ...

Page 2: ...s or injuries resulting from a failure to comply with instructions in this manual Please read and study the entire manual carefully before use The CaviBlaster 2040 ROV must only be operated and maintained by trained personnel This equipment generates high pressure water and is intended for underwater use only Serious personal injury or death may result from improper use ...

Page 3: ...nt 11 3 3 Modification to the Equipment 12 4 0 INSTALLATION 13 4 1 Uncrating and Lifting 13 4 3 Initial Set Up 14 5 0 OPERATION 15 5 1 Preparing the CaviBlaster for Operation 15 5 2 Startup of the CaviBlaster 15 5 3 Normal Operation 16 5 4 Adjusting the CaviBlaster for Maximum Performance 17 5 5 Recommendations for Effective Results 19 6 0 MAINTENANCE 22 6 1 Basic Preventive Maintenance Recommenda...

Page 4: ...4234 U S A Phone 352 275 5319 Page 4 26 LIST OF FIGURES TABLES Figure 1 1 CaviBlaster 2040 ROV Specifications 5 Figure 2 1 CaviBlaster 2040 ROV General Features 7 Figure 4 1 Lifting Guidelines 13 Figure 5 2 Lance Position for Best Cleaning results 19 This space intentionally left blank ...

Page 5: ...PM Nozzle Operating Pressure 4 000 PSI 275 BAR Driver 50M052 Cross Hydraulic Gear Motor Installation Environment Submersible Hydraulic Oil Flow Requirements See below Overall Unit Dimensions L x W x H 30 x 28 x 13 76 cm x 71 cm x 33 cm Maximum Pressure Hose Length 300 LF 100 meters of 3 4 1 9 cm diameter Power Unit Weight Dry 273 LBS 124 KG Hydraulic Power Unit must be capable of operating the wat...

Page 6: ... the energy released by the collapsing bubbles causes marine growth to be removed from the surface The system consists of a portable high pressure pumping unit designed for submersible ROV use and a high pressure cavitation lance connected to ROV manipulator with connecting high pressure hose The CaviBlaster 2040 ROV power unit is a complete plug and play system built on a supporting platform that...

Page 7: ...s Oil pressure compensator pump side must be completely filled with oil Pressure pump pump must be completely filled with oil Secondary relief valve Hydraulic motor Pulsation dampener Pressure regulating valve Water inlet strainers Hydraulic oil connections direction of pump rotation not important High pressure water hose connection Oil pressure compensator fill port cap ...

Page 8: ...erence 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 click on the section name or figure reference to jump to that section The words This space intentionally left blank will appear where there is more than 3 inches of white space ...

Page 9: ... 2013 O M Manual Version 1 0 CaviDyne TM 5077 Fruitville Rd Ste 109 157 Sarasota FL 34234 U S A Phone 352 275 5319 Page 9 26 PSI Pounds Per Square Inch without suffix assumed to be gauge pressure EOS ...

Page 10: ...nly be performed by individuals who are proficient in using this equipment Refer to the applicable section in this manual for the correct procedures prior to any installation setup or maintenance work Note that the oil pressure compensator is not a pressurized component and therefore not a safety hazard It is open at one end and connected to the pressure pump oil chamber at the other end Its purpo...

Page 11: ...ter injection wound 3 2 Personal Protective Equipment Always wear appropriate Personal Protective Equipment PPE when performing maintenance or calibration on this equipment Personnel operating or working in the vicinity of the power unit should wear appropriate hearing protection when operating the CaviBlaster during maintenance or calibration procedures Personnel performing maintenance or calibra...

Page 12: ...ere specifically designed or selected to safely meet the unique high pressure requirements Only replace parts with those recommended by or supplied by CaviDyneTM Any unapproved modifications will void the equipment warranty Unauthorized modification or part substitution can result in serious personal injury or property damage This space intentionally left blank Unauthorized replacement of any part...

Page 13: ...and Lifting Unpack the equipment and inspect for damage If damage is found immediately contact CaviDyneTM and the shipping company If the unit will not be installed immediately provide adequate indoor storage to protect against damage The CaviBlaster power unit should be lifted from underneath Do not use components of the CaviBlaster to lift the entire unit Figure 4 1 Lifting Guidelines Lift from ...

Page 14: ... trapped air 7 Top off oil as required 8 Replace oil pressure compensator fill port cap 9 Set unit back down on vibration mounts 10 It is important that there is no air trapped in the pump oil system 11 Connect hydraulic power unit hoses 12 Connect water pressure hose The CaviBlaster 2040 ROV can be used with seawater but must be flushed and rinsed with fresh water after every use in seawater Fail...

Page 15: ...ter each use 1 Inspect the CaviBlaster power unit hoses JIC fittings and lance for any signs of damage 2 Inspect the water inlet strainer to ensure that it is not clogged See Figure 2 1 Clean if necessary 3 Check for proper pressure pump oil level See pump Owner s Manual found in the Appendix Add oil SAE 30 non detergent if necessary PUMP MUST BE COMPLETELY FILLED Incorrect oils should not be used...

Page 16: ...il fixed Review the safety requirements for PPE and safe operation before proceeding 1 The ROV hydraulic system needs to be operating at a capacity that matches the water pressure pump requirements for the CaviBlaster 2040 ROV to function correctly Unlike gasoline or diesel engines a hydraulic motor will run as fast as the oil supply it receives which means that the hydraulic oil supply must be ad...

Page 17: ... pressure in the hose lines Disconnect the lance from the main hose line Attach the calibration gauge between the main hose line and the lance and tighten the JIC connections See Figure 5 1 Submerge the lance Because of the danger of the operator coming in contact the water stream from the cavitating nozzle CaviDyneTM does NOT recommend calibrating the lance out of the water Use extra care to avoi...

Page 18: ...319 Page 18 26 This space intentionally left blank DO NOT ADJUST THE PRESSURE AT THE LANCE TO MORE THAN 4 000 PSI 275 BAR HIGHER PRESSURE WILL NOT IMPROVE PEFORMANCE AND COULD RESULT IN SERIOUS DAMAGE TO THE PUMP HOSES ARE RATED FOR 4 000 PSI 275 BAR PRESSURES ABOVE 4 000 PSI 275 BAR COULD RESULT IN HOSE FAILURE ...

Page 19: ...ve Results When the ROV operator is ready to commence cleaning operations verify that the lance is securely attached to the manipulator Once the hydraulic power unit is operational and the water jet stream is flowing from the lance the ROV operator has to find the most effective distance between the lance nozzle and the surface being cleaned See Figure 5 2 Calibration gauge Pressure hose Lance ...

Page 20: ... See Figure 5 2 The ROV operator 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 cavitation performance and will degrade the cle...

Page 21: ...ting Down the CaviBlaster 2040 ROV 1 Shut down the ROV hydraulic power unit this will turn off the pressure pump and relieve pressure in the system 2 It is now safe to remove the lance from the water 3 Flush the system and rinse the power unit with fresh water at the end of the day or work shift This space intentionally left blank EOS ...

Page 22: ...essure released from all hoses prior to performing any service work Only replace parts with those supplied or approved by CaviDyneTM 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 DECREA...

Page 23: ...ange if necessary X Whichever occurs first 1 If any hose damage if found replace hose immediately 2 The initial oil change is required after 50 hours of operation See pump manufacturer s literature in the Appendix for additional recommendations 6 3 Pump Service The high pressure water pump requires minimal maintenance The pump oil should be checked on a regular basis The pump crankcase should be C...

Page 24: ...ents in the area The water jet from the lance can travel 30 to 40 feet 9 to 12 meters b Connect the hydraulic motor to a hydraulic power unit and start the hydraulic power unit Verify that the hydraulic power unit is delivering the correct RPM 1160 and HP 55 required to operate the water pressure pump c If water is leaking out of the hose fittings or connections replace the damaged component and s...

Page 25: ...QUANTITY PER ASSEMBLY PART DESCRIPTION PART NUMBER 2 2 Water inlet strainer CASS 20 1 100 316 1 1 Pump seal kit 31280 1 1 Pump valve kit 31292 1 1 Pressure regulator CAT 7024 100 1 1 Unloader repair kit UB 502 K 1 1 Oil pressure compensator 50MH52DBCSC All parts can be ordered from CAVIDYNE TM LLC 5077 Fruitville Rd Ste 109 157 Sarasota FL 34235 USA Phone 352 275 5319 Email support cavidyne com ww...

Page 26: ...NDIX COMPONENT LITERATURE Cross Hydraulic Gear Motor Model 50M052 Spec Sheet CAT Pump Model 3560 Pump Spec Sheet Pump Exploded View Pump Dimensions Pump Service Guide Pump Torque Specs CAT Pressure Regulator Model 7024 100 Valve Spec Sheet Udor Model UB 402 Unloader Valve Valve Spec Sheet Warranties Cavidyne Cross CAT Udor USA EOS ...

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