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Clemco Zero Pulsar 3D, Manual

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Clemco Zero Pulsar 3D Manual Download Page 4

 

PULSAR

®

 3D SUCTION BLAST CABINET 

Page 3 

 

 

 

 

 

© 2020 CLEMCO INDUSTRIES CORP.  

  www.clemcoindustries.com  

  Manual No. 29374

 

 

 

                                             

 

 

Figure 1 

 

1.5 

Theory of Operation 

 

1.5.1 

Once  the  cabinet  is  correctly  set  up  and  turned 

on, the cabinet is then ready for operation by actuation of 
the  foot  pedal.  Fully  depressing  down  on  the  foot  pedal 
causes  air  to  flow  through  the  blast  gun.  The  partial 
vacuum  created  by  air  moving  through  the  gun  draws 
media  into  the  blast-gun  mixing  chamber.  The  media 
mixes with the air stream and is propelled out the nozzle. 
After  striking  the  object  being  blasted,  the  blast  media, 
fines,  dust,  and  byproducts  generated  by  blasting  fall 
through the grate into the cabinet hopper. These particles 
are then drawn into the reclaimer for separation. Dust and 
fines are first separated from reusable media and pass into 
the dust collector. Next, the media is screened for oversize 
particles and returned to the reclaimer hopper for reuse. 
Dust  and  fines  entering  the  dust  collector  are  removed 
from  the  air  stream  as  they  pass  through  the  filters, 
discharging  clean  air.  When  the  foot  pedal  is  released, 
blasting stops. 

1.6 

Dust Collector 

 
1.6.1 

The  Pulsar

®

  3D  cartridge  dust  collector  is  not 

suitable  for  use  in  applications  that  generate  dust  from 
lead coatings, heavy metals, or any other toxic materials. 

 

 

 



Prolonged exposure to any dust can result in 
serious lung disease and death. Short-term 
ingestion of toxic materials, such as lead dust 
or dust from other heavy metals and corrosives, 
can cause serious respiratory injury or death. 
This machine is not to be used in applications 
which generate dust from lead coatings, heavy 
metals or any other toxic materials. Identify all 
materials that are to be removed by blasting 
and obtain a safety data sheet (SDS) for the 
blast media.

 

 

Pilot  Regulator 
(blast pressure) 

Foot Pedal 

BNP

TM

 Blast Gun 

Door Interlock Valve 
and Actuator 

Metering Valve 

Dust Collector 

Pulse Reservoir 

Reclaimer 

Waste Drum 

Summary of Contents for Zero Pulsar 3D

Page 1: ...ormation 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 representations are intended or made as to the suitability of engineering balance of or compliance with regulations or standard practice of any such combination of products or components the user may employ Thi...

Page 2: ...onsidered important but not hazard related if not avoided could result in property damage Caution indicates a hazardous situation that if not avoided could result in minor or moderate injury Warning indicates a hazardous situation that if not avoided could result in death or serious injury D anger indicates a hazardous situation that if not avoided will result in death or serious injury 1 3 Table ...

Page 3: ...a consumption 7 2 Reduction in blast cleaning rate 7 3 Plugged nozzle 7 4 Media bridging 7 5 Neither media nor air comes out the nozzle 7 6 Blockage in media hose 7 7 Poor suction in media hose 7 8 Air only no media from nozzle 7 9 Blowback through media hose 7 10 Blasting does not begin when foot pedal is pressed 7 11 Blasting continues after foot pedal is released 7 12 Media buildup in cabinet h...

Page 4: ...r oversize particles and returned to the reclaimer hopper for reuse Dust and fines entering the dust collector are removed from the air stream as they pass through the filters discharging clean air When the foot pedal is released blasting stops 1 6 Dust Collector 1 6 1 The Pulsar 3D cartridge dust collector is not suitable for use in applications that generate dust from lead coatings heavy metals ...

Page 5: ...r to Section 8 2 Item 9 1 8 5 Glass Bead Recommended range is 6 thru 13 Most beads are treated to ensure free flow operation even under moderately high humidity conditions Glass beads subjected to excessive moisture may be reused after thorough drying and breaking up of any clumps 1 8 6 Fine Mesh Media In most cases media finer than 180 will carry over to the dust collector 1 8 7 Lightweight Media...

Page 6: ...id the risk of injury from compressed air install an isolation valve and bleed off valve where the air supply is tapped into the compressed air system This enables a lockout and tagout procedure and depressurization of the compressed air line before performing maintenance Hose disconnection while under pressure can cause serious injury or death Use safety lock pins or safety wire to lock twist on ...

Page 7: ...ing 3 2 Media Loading 3 2 1 Media loading With the exhauster OFF add clean dry media by pouring it through the reclaimer door Do not fill above the cone on the reclaimer Do not pour media directly into the cabinet hopper as overfilling may occur Overfilling will result in media carryover to the dust collector and possible blockage in the conveying hose Refill only after all media has been recovere...

Page 8: ...ressure regulator to the required blast pressure per Section 4 1 The regulator is located on the front right leg of the cabinet 3 5 7 Insert hands into rubber gloves 3 5 8 To blast hold the gun firmly point the gun toward the object to be blasted and apply pressure to the top of the foot pedal blasting will begin almost immediately Shut down the cabinet immediately if dust discharges from the dust...

Page 9: ...ting starts Once operating pressure is set push the knob in to lock it to maintain the setting 4 2 Pulse Pressure Figure 6 Do not pulse new dust collectors or replacement cartridges until the cartridge is properly seasoned Refer to Section 6 8 Pulsing unseasoned cartridges can cause premature cartridge failure or decrease the efficiency of dust collector 4 2 1 The pulse pressure regulator located ...

Page 10: ...el Refer to Figure 8 4 3 6 Needle placement Figure 7 shows the manometer setup for taking both periodic and frequent static pressure readings 4 3 6 1 Taking frequent readings using a permanent fitting A permanent fitting may be installed in the reclaimer wall as shown in Figure 7 for taking frequent static pressure readings Permanent fittings must have a barb to accommodate the 3 16 ID tubing and ...

Page 11: ...system Doing so can result in serious injury from unexpected blasting 4 5 1 The door interlock disables the blasting control circuit when the door is open To enable blasting the door interlock switch must be engaged when door is closed The interlock is set at the factory and does not normally require field adjustment unless parts are replaced When adjustment is required proceed as follows 4 5 2 Cl...

Page 12: ...the fines allow the media to go through several cycles before further adjustment Lower the door to remove more fines raise the door to retain more media The following are examples of the door slide setting during factory tests 1 13 glass beads slotted door shut 2 8 glass beads slotted door open about 3 16 3 11 glass beads slotted door open about 3 32 4 180 mesh aluminum oxide slotted door open abo...

Page 13: ... If the filter does not remove enough moisture to keep media dry and flowing it may be necessary to install an air dryer or aftercooler in the compressed air supply line 5 1 4 Inspect dust container Empty the dust container regularly Start by checking the container at least daily and when adding media then adjust frequency based on usage contamination and friability of the media 5 1 4 1 Turn off t...

Page 14: ... MAINTENANCE Prior to doing any maintenance or opening the dust collector the employer must meet required OSHA standards including but not limited to 29CFR 1910 for Appropriate Respirator Protective Clothing Toxic and Hazardous Substances Fall Protection Lockout and Tagout All dust is hazardous to breath toxicity and health risk vary with type of dust generated by blasting Prolonged exposure to an...

Page 15: ...tion 6 4 6 3 4 Set the new window squarely over the window opening making sure that all edges of the window are centered and overlapping the window gasket and that the window is resting on the window support tabs 6 3 5 Swing the window frame into place and tighten the frame nuts 6 4 Window Gasket Replacement Figure 15 6 4 1 Inspect the gaskets when changing the view window Replace the window frame...

Page 16: ...e the cover as noted in Section 6 6 1 Move the light module off the diffuser lens and remove the lens 6 6 2 2 Remove all the old gasket material and clean the surface of the cabinet 6 6 2 3 Lay a section of strip gasket along the edge of the opening and cut to length allowing 3 4 overlap on each end Peel a short section of adhesive backing and adhere the strip gasket to the top edge of the light o...

Page 17: ...stic bag over the cartridge as it is removed 6 7 4 After the cartridge is removed clean the inside of the collector to remove loose dust or hardened dust clumps particularly from the cartridge sealing surface front side of the cartridge sheet 6 7 5 A new rubber gasket comes with the new cartridge Use the new gasket reuse the fasters and install the cartridge in reverse order 6 7 6 Inspect the cove...

Page 18: ...terlock system Follow all OSHA regulations including lockout and tagout procedures 7 1 Poor visibility 7 1 1 Dirty filter cartridge Empty the dust container Pulse cartridge several times per Section 5 2 4 Inspect cartridge and replace when necessary 7 1 2 Exhauster motor not operating Check voltage to motor and motor wiring 7 1 3 Using friable media that rapidly breaks down or using media that is ...

Page 19: ...sorption from ambient air 7 5 2 To avoid contaminating media from the workpiece all parts put into the cabinet should be clean and dry If parts are oily or greasy degrease and dry them prior to blasting 7 5 3 Moist compressed air may be due to a faulty compressor that overheats or pumps oil or moisture into the air line too long of an air line permitting moisture to condense on the inside or from ...

Page 20: ... Foot pedal valve malfunction Check foot pedal alignment and inlet and outlet lines for pressure 7 11 4 Make sure lines are not reversed on the foot pedal or pilot regulator Refer to the schematic on Page 25 Figure 28 7 11 5 Pressure regulator may be set to low or OFF Adjust blast pressure per Section 4 1 7 11 6 Make sure the air compressor is operating and air supply valves are open 7 11 7 Check ...

Page 21: ... or missing Remove the two screws on the bottom of the pedal and remove the switch and cam follower assembly Center the cam follower and replace roll pins as needed to hold the cam follower in place Refer to Figure 21 7 17 4 Check alignment of pulse valve cam follower With the exhauster running and with blast pressure adjusted to 0 psi hold the foot pedal in hand and fully press the pedal top The ...

Page 22: ...blem is likely in the diaphragm pulse valve Inspect the diaphragm for wear or damage If it does not spurt air the 3 way valve is not functioning Replace the 3 way valve NOTE The 3 way valve at the foot pedal and the 3 way on the diaphragm pulse valve are identical If there is doubt as to whether either 3 way valve is functional the valves may be tested by swapping one with the other 7 17 5 2 Hold ...

Page 23: ...swivel 15002 9 Nozzle ceramic No 5 green tip 11930 Nozzle tungsten carbide No 5 13118 Nozzle boron carbide No 5 11935 10 Hose 1 2 air specify ft required 12472 11 Hose media clear specify ft required 12476 12 Adjusting tool correctly positions air jet 19041 Figure 23 8 3 View Window Assembly Figure 24 Item Description Stock No 1 Window glass 10 x 18 laminated 29915 2 Gasket 5 16 x 3 4 applied to c...

Page 24: ...Screw socket head 1 4 nf x 3 4 03086 5 Spring 1 1 4 OD x 3 1 2 20121 6 Adaptor 10 32 thread x 1 8 barb 11731 7 Screw fh 10 32 x 1 2 19571 8 Tubing 1 8 ID twin per foot 12 ft req 19577 9 Screw 8 32 x 3 8 11389 10 Bumper neoprene 21522 11 Cam follower 19576 12 Spacer 19258 13 Valve 3 way pulse valve 12202 14 Roll pin 1 8 20479 15 Bracket valve mount 22858 16 Fitting 1 8 NPT elbow x 1 8 barb 11733 17...

Page 25: ...ht hand only 29906 10 Clamp for clamp attached glove 11576 11 Hose clamp 2 1 2 02817 12 Flex hose 1 3 4 29922 13 Adaptor pipe flex hose 29925 14 Gasket flex hose adaptor pipe 00187 16 Detent sleeve door interlock 15042 17 Over travel stop door interlock 20004 18 Air valve 3 way door interlock 12202 19 Gauge 1 8 NPT cbm pressure 01908 20 Fitting 1 8 NPT elbow x 1 8 barb 11733 21 Mini regulator 1 8 ...

Page 26: ...1 2 01773 15 Hose 1 2 air specify ft required 12472 16 BNP No 4 gun assembly without nozzle 12301 17 Hose media clear specify ft required 12476 18 Pilot operated regulator 1 2 11345 19 Pipe cross 1 2 10254 20 Nipple 1 4 hex brass 02808 21 Metering valve assembly BNP 12417 22 1 8 Male hose x NPT fitting 11732 23 Bushing 1 4 x 1 8 hex 02010 24 Nipple 1 4 hex brass 01962 25 Filter 1 2 NPT air 01308 2...

Page 27: ...quired 00187 11 Hose 1 2 air 4 feet required 12472 12 Grommet rubber 11798 13 Hose 1 2 clear media 4 ft Required 12476 14 Clamp 2 1 2 02817 15 Hose 1 3 4 flex 29922 16 Wear plate reclaimer 24969 17 Nut 1 4 NC wing 03113 18 Door with slide order gaskets separately 24967 19 Screw 10 x 3 4 self drilling 12722 20 Adaptor reclaimer outlet pipe 25852 21 Pipe nipple 3 8 x 1 SCH 40 12747 22 Elbow 3 8 90 d...

Page 28: ... diaphragm pulse 25867 11 Elbow 1 8 NPT brass st 03993 12 Nipple 1 8 brass hex 01945 13 Valve 3 way 12202 14 Actuator air pilot 19123 15 Fitting straight 1 8 NPT x 1 8 barb 11732 16 Petcock drain 01993 17 Fitting straight 1 4 NPT x 3 8 tube 11736 18 Clamp 4 11577 19 Hose 4 unlined flex 1 ft minimum 12447 20 Lid and locking ring dust drum 23419 21 Liners drum pack of 5 28621 22 Dust drum 3 5 gallon...

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