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DirectFlo DF1400

Chapter 5: Trouble-Shooting and Repair

Comco Inc.

5-2

Issue Date: January 2009

Trouble-shooting

This chapter explains what to do if you have any problems with the DirectFlo.
The first part of the chapter describes some of the problems that may occur, and
the second part contains detailed repair procedures.

NOTE: Improper repairs may void your warranty. If you have any

questions, consult with Comco before you do any work on
the inside of the DirectFlo DF1400.

Most problems that can occur with your DirectFlo will fall into either one of two
categories:

1)

No air flow - Nothing happens when you depress the footswitch.
Neither air nor abrasive is expelled from the nozzle.

2)

No abrasive flow - Air flows freely from the nozzle when the
footswitch is depressed. However, there appears to be no
abrasive in the air stream, or it flows erratically.

The tables that follow address each of these conditions specifically.

Customer Service

Comco’s Customer Service Department is open Monday through Friday from
6:30am to 4:30pm, Pacific Time, to help you with any problems you may have
with your DirectFlo. The telephone numbers and FAX number are listed below:

Phone: 1-818-841-5500

FAX: 1-818-955-8365

Check our website for additional tech support information and videos:

www.comcoinc.com

You may also e-mail your questions to:

[email protected]

(Rev 3/21)

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Summary of Contents for DirectFlo DF1400 Series

Page 1: ...400 Issue Date January 2009 This manual covers all variations of the DF1400 series DF1400 1 DF1400 2 ETC Comco Inc 2151 N Lincoln Street Burbank California 91504 USA Phone 818 841 5500 FAX 818 955 8365 www comcoinc com Book P N PF1430 File DF1400 doc ...

Page 2: ...ure 2 2 DirectFlo Reference Sheet 2 4 What You Received with the DirectFlo 2 5 Basic Components of the DirectFlo 2 6 Figure 2 3 External Component Locations 2 7 Setup and Test 2 8 Figure 2 4 Tank Inspection 2 9 Chapter 3 Using the DirectFlo 3 1 This chapter discusses the selection of key operating parameters such as abrasives and nozzles and tells you how to operate the DirectFlo for maximum effic...

Page 3: ...ement Parts 5 3 Common Problems Causes and Solutions 5 4 Table 5 1 No Air Flow 5 4 Table 5 2 No Abrasive Flow 5 5 Clogging 5 6 Tank Cover 5 7 Replacing the Abrasive Hose and Fittings 5 8 Figure 5 1 5 9 Inspecting and Repairing the PowderGate 5 13 Figure 5 2 5 13 Inspecting and Repairing the Modulator 5 15 Figure 5 3 Modulator Assembly 5 16 Air Pressure Regulator 5 17 Chapter 6 Optional Equipment a...

Page 4: ...ne of the following 1 Send replacement parts to the customer to be installed by the customer 2 Repair the unit at the customer s facility or 3 Request that the unit be returned to the Comco factory Comco shall furnish any replacement parts without cost F O B the Comco factory in Burbank California provided that Comco is notified of the defect within the warranty period Any defective parts shall be...

Page 5: ... DirectFlo uses pressurized air to perform its basic function While Comco s blasting machines incorporate relief valves and check valves to minimize the risk of an accident related to air pressure Comco also recommends the following The air supply system should have a shutoff valve located upstream of the blasting machine so that the supply pressure can be turned off independently of the blaster P...

Page 6: ... s cover will be removed Do not operate the DirectFlo with its cover removed Keep the interior of the DirectFlo clean of dust powder and any foreign object or substance that could conduct electricity CAUTION Some abrasive powders are conductive and may present a hazard if allowed to accumulate inside the machine Working with the Abrasive Media The DirectFlo uses several types of abrasive media tha...

Page 7: ... eyes Gloves may be necessary for operators who are sensitive to powders or dust on their skin Some powders if allowed to collect inside the machine may cause electrical shorts Material safety data sheets MSDS s for all abrasives distributed by Comco are available from the Comco factory Every powder shipment includes an MSDS Contact the Comco Customer Service department to obtain extra copies of a...

Page 8: ...Machinery cont d The following warning labels pictograms are utilized in the DirectFlo CE European versions Symbol Meaning ELECTRICAL HAZARD HAND PROTECTION RECOMMENDED WHERE APPROPRIATE EYE PROTECTION RECOMMENDED WHERE APPROPRIATE RESPIRATORY PROTECTION RECOMMENDED WHERE APPROPRIATE ...

Page 9: ...lo DF1400 Chapter 1 The DirectFlo 1400 Comco Inc 1 1 Issue Date January 2009 Chapter 1 The DirectFlo DF1400 In This Chapter A general description of the DirectFlo How the DirectFlo works Detail specifications ...

Page 10: ... consists principally of an inlet air valve rear panel air pressure regulator with gage modulator internal abrasive powder tank and mixing chamber The abrasive PowderGate valve assembly to stop and start the abrasive flow the footswitch to actuate it and a handpiece that holds the precision nozzle complete the machine All the component parts are manufactured to the highest standards and are design...

Page 11: ... passes through an open or de energized modulator assembly and into the mixing chamber and abrasive tank Air cannot escape through the nozzle because the PowderGate or shut off assembly is closed The air pressure inside the system builds up until it reaches the regulated pressure Figure 1 2 DirectFlo Pressurized The DirectFlo as shown in the illustration above is now pressurized and ready to use T...

Page 12: ...es and de energizes it 60 times every second Refer to Figure 1 4 item 2 At the beginning of the operating cycle as shown in Figure 1 3 below the hose pinch is opened Before the modulator has had a chance to energize regulated air flows freely through the open modulator valve the mixing chamber and out the nozzle Figure 1 3 Modulator Open Since the air flowing from the regulator into the mixing cha...

Page 13: ...again de energized and opens to allow pressurized air to freely flow into the mixing chamber and out the nozzle This forces air back into the abrasive tank stabilizing the pressure between the tank and the mixing chamber refer back to Figure 1 3 Each cycle happens very quickly 50 60 times per second The end result of this stop start action of the modulator is a consistent stream of abrasive out th...

Page 14: ...Max Electrical Voltage 2 115 or 230 10 20 VAC Frequency 50 60 Hz Power Less than 100 Watts Physical Width 18 in 46 cm Depth 16 in 40 cm Height Tall tank model 17 in 43 cm 25 2 in 64 cm Weight Tall tank model 64 lbs 29 5 kg 72 lbs 32 6 kg Tank Size Tall tank model 200 in3 3300 cm3 400 in3 6600 cm3 Tank Capacity abrasive 10 lbs 4 5 kg 20 lbs 9 kg During normal operation employing a 0 060 diameter no...

Page 15: ...d Comco Inc 2 1 Issue Date January 2009 Chapter 2 Getting Started In This Chapter The work area required to properly use the DirectFlo What you received with the DirectFlo Basic components of the DirectFlo Setting up and testing the DirectFlo ...

Page 16: ...each of these items Refer to figure 2 1 to see how these items work together as a complete system WorkStation A suitable hood or box providing a means of working with the abrasive material without contaminating the atmosphere of the room is required It must protect the operator s face and provide adequate light The Comco WS2200 and WS6000 WorkStations are designed for this purpose Dust Collector I...

Page 17: ...cro abrasive Blasting System Requirements Electric Power A source of 115 or 230 VAC 50 60 Hz capable of providing 100 watts is required for the DF1400 If the WS2200 or WS6000 WorkStation is used it requires 40 watts The DC2100 Dust Collector if used requires about 16 amps 115 VAC for its 1 HP motor Actual voltage required for each machine will be found on the nameplate ...

Page 18: ... Verify that the hose from the dust collector is connected to the 4 collar on the back panel of the WorkStation For optimum dust collection the hose should be as short as possible 2 Position the DirectFlo on top or along side of the WorkStation 3 Verify the DirectFlo is connected to a dry air supply of 80 140 PSIG Bottled CO2 or nitrogen is recommended if dry air from a compressor is not available...

Page 19: ...ded and how to set up and test your micro abrasive blasting system for proper operation Once you receive your DirectFlo DF1400 check the contents of the shipping carton to make sure that you have received all of the items Besides this manual and the Reference Sheet pictured on the previous page you should find the standard Accessory Parts Kit Note that two additional items a 025 tank orifice MB140...

Page 20: ...front of the unit indicates the air pressure in the abrasive tank Typically operating pressure selected for the process will be between 40 psig and 125 psig Abrasive Blend Control The Abrasive Blend Control knob controls the ratio of the air abrasive mixture Turning the knob clockwise increases the concentration of media in the air stream The Abrasive Blend control is designed for fine tuning the ...

Page 21: ...omco Inc 2 7 Issue Date January 2009 Figure 2 3 External Component Locations PRESSURE GAGE POWER SWITCH ELECTRICAL POWER CONNECTION AIR PRESSURE CONTROL KNOB POWDERGATE OUTPUT VENT HOSE ABRASIVE BLEND CONTROL FOOTSWITCH CONNECTION AIR IN COUPLING ...

Page 22: ... tank cover and check to make sure that the O rings are not damaged and that the sealing surface is clean 5 Wipe off the top surface of the tank and replace the tank cover Be sure that the tank cover is properly oriented on the tank with the vent holes at the front and rear Swing the bolts up into the slots in the cover and tighten the nuts firmly but not too tight 6 Remove the protective red cap ...

Page 23: ...DirectFlo DF1400 Chapter 2 Getting Started Comco Inc 2 9 Issue Date January 2009 Figure 2 4 Tank Inspection SWING BOLTS NUTS 4 POWDER BASKET TANK COVER ...

Page 24: ...e grips located in the back of the workstation Push the tubing through the grip 1 to 2 inches and hand tighten the grip s nut to secure the tubing When connecting the DirectFlo to an automated system the vent tube grips can be found on or near the dust collection outlet of the blast chamber CAUTION The air that comes out of the vent hose will contain abrasive Place the free end of the vent hose in...

Page 25: ...esult of abrasive flow especially the WorkStation glass window 18 Step on the footswitch again As air escapes from the nozzle watch the pressure gage The needle should remain steady or oscillate slightly around the set pressure If the air pressure drops significantly check your air source to ensure that it can consistently deliver at least 6 SCFM of air 19 Press down and release the footswitch sev...

Page 26: ...DirectFlo DF1400 Chapter 2 Getting Started Comco Inc 2 12 Issue Date January 2009 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 27: ...Flo DF1400 Chapter 3 Using the DirectFlo Comco Inc 3 1 Issue Date January 2009 Chapter 3 Using the DirectFlo In This Chapter Abrasive selection Orifice and Nozzle selection General operation of the DirectFlo ...

Page 28: ...ght abrasive you can lightly clean soft materials or deburr machined metal parts Once the correct abrasive is chosen the remaining factors that affect the abrasive action are the number of particles striking the work area the velocity of the particles and the angle of the blast These factors are controlled by the DirectFlo through the following operator selections Tank Orifice Size Nozzle Size Noz...

Page 29: ...thin this chapter The Air Pressure The higher the pressure the faster the work will be abraded Nozzles hoses and fittings also wear out faster with higher pressures See the Air Pressure heading within this chapter The Distance between the nozzle and the work Up to a point the closer the nozzle gets to the work the faster the material will be removed beneath the nozzle A distance of about 5 8 times...

Page 30: ...erials with much more efficiency since it is less likely to shatter on impact Particle Size Choosing the abrasive material defines both hardness and sharpness so the only variable remaining is size Many different sizes of abrasive media are available for use with the DirectFlo see Table 3 2 Particle sizes between 10 and 300 microns 800 75 grit work best Since the very small orifices in the DirectF...

Page 31: ... Silicon Carbide 20 0 0008 10 40 The fastest cutting of the standard abrasives The best abrasive to deburr stainless steel and titanium parts Does not absorb moisture Dark gray or black in color F Silicon Carbide 50 0 002 30 80 G Sodium Bicarbonate 50 0 002 20 150 A very gentle abrasive good for very light cutting of soft materials Can be used to remove conformal coating from PCBs Water soluble an...

Page 32: ... 30 0 040 12 6 X 10 4 MB1409 40 0 060 28 3 X 10 4 MB1409 60 Some judgment is required in selecting an orifice A very small orifice should not be used with powders of large particle size Likewise a very large orifice may cause a small nozzle to plug from excessive powder in the line See Table 3 3 for guidelines in selecting orifice size The DF1400 as shipped from the factory is equipped with the 0 ...

Page 33: ...rticle Size Recommended Tank Orifice Average Particle Range Microns Micron Inch 10 0 0004 5 30 0 025 20 0 0008 10 40 0 025 25 0 001 15 45 0 025 50 0 002 30 80 0 025 150 0 006 65 200 0 030 200 0 008 80 300 0 040 250 0 010 150 300 0 060 Figure 3 1 Changing the Tank Orifice Rev 5 2014 TANK COVER NUTS ORIFICE POWDER BASKET TANK COVER ...

Page 34: ...ed if a rectangular nozzle is used and properly oriented with respect to the cut This may require fixturing if precision is required As shipped from the factory the DF1400 has the 0 060 diameter red nozzle installed in the handpiece This nozzle will provide the best cutting for general applications and will handle all of Comco s abrasives Nozzle Selection The nozzles provided with your DirectFlo a...

Page 35: ...08 x 0 150 0 2 x 3 8 0 195 0 018 0 040 E MB1500 32 Blue 0 012 x 0 150 0 3 x 3 8 0 195 0 018 0 046 Straight Round Nozzles with Extended Carbides 1 5 inches long Requires Comco Nozzle Adapter PF2044 see Figure 3 2 C MB1503 2 Green 0 030 0 8 0 074 0 018 0 040 C MB1503 3 Yellow 0 046 1 2 0 120 0 018 0 046 90 Degree Angle Nozzles Requires Comco Nozzle Adapter PF2044 see Figure 3 2 D MB1501 14 Green 0 0...

Page 36: ...ion increases as the nozzle is moved closer to the work surface it should be noted that the material removal rate reaches a maximum when the spacing between the nozzle tip and the work is about 5 8 times the nozzle opening diameter Moving the nozzle closer than this tends to start slowing the cutting rate as particles bounce back and collide with each other Also as the hole becomes deeper the diam...

Page 37: ...port for additional information about splitter capabilities Air Pressure The simplest method of changing cutting speed is to vary the air pressure to the tank with the Air Pressure adjustment knob Increasing the pressure increases the velocity of the abrasive particles Therefore the higher the pressure the faster the work surface will be abraded It should be mentioned that the nozzle hose and fitt...

Page 38: ...o use the DirectFlo Before proceeding make sure you have Reviewed the safety precautions in the introductory section of this manual Properly set up your DirectFlo according to the procedures in Chapter 2 Selected the proper abrasive for your application Installed the proper tank orifice for the abrasive powder you are using Selected the proper nozzle for your application ...

Page 39: ...ank vent hose is inserted into the back of the WorkStation or dust collector hose 3 Depress the tank cover flapper see Figure 3 3 and using the funnel from the accessory kit pour the selected abrasive powder into the tank filling it at least half full Do not overfill Tap the flapper as it closes so that any powder on it will be dislodged into the tank and not interfere with sealing of the O ring F...

Page 40: ...lo Comco Inc 3 14 Issue Date January 2009 Figure 3 4 Controls and Indicators PRESSURE GAGE POWER SWITCH AIR IN COUPLING ELECTRICAL POWER CONNECTION AIR PRESSURE CONTROL KNOB POWDERGATE OUTPUT VENT HOSE ABRASIVE BLEND CONTROL FOOTSWITCH CONNECTION ...

Page 41: ...ected to the WorkStation 3 Install the appropriate nozzle in the handpiece being sure that the O ring is in place and firmly seat the nozzle finger tight The machine is initially equipped with a 0 060 diameter nozzle red which is suitable for most abrasives and cutting purposes 4 Make sure the handpiece is inserted into the WorkStation through one of the side openings Grasp it firmly as if it were...

Page 42: ...sing the Abrasive Blend adjustment knob Turning the knob counterclockwise decreases the media concentration 10 When finished blasting you may shut down the DirectFlo by pressing the Power switch to OFF The tank pressure will automatically vent through the vent hose Tank pressure will take 10 to 15 seconds to fully vent If the DirectFlo is equipped with an extended powder tank it will take between ...

Page 43: ...om both the basket and the tank The preferred method is by using a vacuum or slip the dust collector hose off the back of the WorkStation and use it to vacuum the inside of the basket tank and cover 6 Insert the basket back into the tank by pushing down with a slight twist to seat the O ring 7 Wipe off all abrasive on the tank top surface and the tank cover O rings to ensure that the sealing surfa...

Page 44: ...DirectFlo DF1400 Chapter 3 Using the DirectFlo Comco Inc 3 18 Issue Date January 2009 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 45: ...DirectFlo DF1400 Chapter 4 Maintenance Comco Inc 4 1 Issue Date January 2009 Chapter 4 Maintenance In This Chapter Maintenance intervals Extending the life of wear items Replacing worn out components ...

Page 46: ...or repair task Unless specifically directed otherwise ALWAYS depressurize the unit and unplug it before removing the cover or doing any maintenance or repairs There may be sharp edges inside the cabinet which could cause injury to personnel or damage to components Observe all safety precautions provided within this manual Tools In addition to standard hand tools the following items may be required...

Page 47: ...r air leakage out of nozzle when blast is off Tank Orifice Inspect the tank orifice for excessive wear or clogging Air Dryer Service Air Dryer Inspect powder storage conditions 6 months to 1 year Entire Unit Inspect the power cord and footswitch cable Remove the cover and check for internal leaks Check all of the items that follow in this table Modulator Inspect the modulator for wear see directio...

Page 48: ... general rule the smaller the opening through which the abrasives must flow the greater the possibility of wear Parts also subject to wear are the tank cover O rings and the modulator Abrasive Hose With the machine off and depressurized squeeze the Abrasive Hose between thumb and forefinger in the area along the first 2 3 inches adjacent to the PowderGate output It should be evenly firm along its ...

Page 49: ...r The abrasive nature of the blasting media will cause the orifice to erode over time increasing in diameter As the size of the orifice changes the abrasive flow increases potentially clogging the nozzle or reducing the efficiency of the abrasive PowderGate The PowderGate is a control valve for turning ON and OFF the abrasive flow to the nozzle The PowderGate has been designed for minimal maintena...

Page 50: ... and its close proximity to the abrasive in the mixing chamber the mechanical part of the modulator the modulator housing assembly is considered a wear point and should be inspected on a regular basis The frequency with which the modulator should be inspected depends on machine usage Applications that include heavy use or very aggressive abrasives may require checking the modulator on a monthly ba...

Page 51: ...nside of the DirectFlo for obvious leaks Clean thoroughly with a small brush and vacuum hose never use air or try to blow off abrasive Filter Bowl The filter is part of the Air Pressure Regulator assembly and is designed to trap abrasive that may otherwise be forced back into the clean air side of the DF1400 causing major component failures Check and empty the filter bowl unscrew it every six mont...

Page 52: ...4 ABRASIVE HOSE ST5023 FLAPPER O RING ST5495 TANK COVER O RING ST5496 TANK VENT O RING PF2055 FEEDTHRU BUSHING ST5504 BASKET O RING MB1409 xx TANK ORIFICE PF2040 MODULATOR HOUSING ASSEMBLY MB1653 NOSEPIECE PF2189 2 VALVE SEAT ASSEMBLY ST6267 FILTER ELEMENT PF2066 HANDPIECE TUBE ST5508 NOZZLE O RING RIRi PF2110 x NOZZLE PF2090 NOZZLE NOSE ASSEMBLY ST4209 TUBING FERRULE SET PF2083 3 8 ABRASIVE HOSE ...

Page 53: ...or Empty the spent abrasive from the dust collector on a regular basis Typically this should be done monthly However in high use facilities it should be done weekly WorkStation Make sure the WorkStation has good air draw and remains clear of abrasive build up If abrasive begins to build up refer to the above paragraph on Dust Collector Keep the glass window clean and replace it if it becomes damag...

Page 54: ... valve and contaminate the powder To prevent this form of contamination fill the tank with only the amount of abrasive you expect to use that day Only fill the tank at the beginning of the work shift Don t fill the tank and let it sit overnight The most common cause of moisture contamination however comes from the air compressor that feeds the DirectFlo Water condensation occurs in compressed air ...

Page 55: ...ble shooting and Repair In This Chapter What to look for if your DirectFlo does not operate properly and how to determine the specific problem How to correct most problems which may develop with the DirectFlo How to contact Comco s Customer Service Department How to order replacement parts for the DirectFlo ...

Page 56: ...flow Nothing happens when you depress the footswitch Neither air nor abrasive is expelled from the nozzle 2 No abrasive flow Air flows freely from the nozzle when the footswitch is depressed However there appears to be no abrasive in the air stream or it flows erratically The tables that follow address each of these conditions specifically Customer Service Comco s Customer Service Department is op...

Page 57: ...sts Lists of DF1400 replacement parts accessories and supplies are provided in this manual as follows Items Location Accessories A listing of all components in the accessory kit Chapter 2 Getting Started and Appendix A Parts Lists Supplies Lists of abrasives nozzles and tank orifices Chapter 3 Using the DirectFlo DF1400 Recommended Spare Parts List of normal wear items Appendix A Parts Lists Major...

Page 58: ...e indicate pressure in the system Verify that shop air pressure of 80 140 psig is supplied to the DirectFlo Is the nozzle plugged If you are using a nozzle with the nozzle adapter remove the nozzle and depress the footswitch If a blast of abrasive occurs the nozzle was plugged Tap it on the workbench back end down Discard the nozzle if it remains plugged If plugging recurs either the tank is relea...

Page 59: ... remove the tank cover without disturbing the powder in the tank Note if there are obvious holes or cracks in the powder leading down to the orifice This is caused by damp powder or moisture in the air supply Check the air supply and the powder storage conditions Service the air dryer or install one Is the tank orifice plugged Remove the powder in the tank following normal procedures Remove the or...

Page 60: ...or the powder to get from the tank to the mixing chamber a clog here restricts or prevents powder flow If air is flowing freely when the footswitch is depressed but there seems to be no abrasive in the air stream first check for moisture contamination as described in the previous chapter Then remove the tank orifice see Chapter 3 Changing the Tank Orifice check it for clogging and clean if necessa...

Page 61: ...2 Remove the tank cover by loosening the four retaining bolts 3 Using a 3 32 Allen wrench remove the flapper valve Replace the O ring if necessary see procedure below 4 Install the new flapper valve MB1145 5 Install the tank cover Tank Cover O ring Replacement Procedure 1 Turn Power OFF and depressurize unit 2 Remove the tank cover by loosening the four retaining bolts 3 Using long nose pliers rem...

Page 62: ...zzle is not tightened firmly into the nose abrasive leakage will wear away the threads and the nozzle will not fit properly Refer to Appendix B Figure 8 Handpiece Nose Replacement Procedure PF2090 1 Remove the nozzle 2 Unscrew the handpiece tube from the nosepiece and slide it back Because of the static guard spring on the hose it may be necessary to hold or tape the handpiece back out of the way ...

Page 63: ...lide the nut and new ferrules onto the tubing end as shown in Fig 5 8 2a 5 Insert the tubing end into the PowderGate s output connector and hold the tubing straight into the fitting with its end firmly seated against the shoulder inside the fitting 6 Slide the ferrules up to the fitting and thread the nut onto the connector finger tight 7 Using a 3 4 open end wrench tighten the nut onto the fittin...

Page 64: ... to the fitting s tube Leaks Small leaks can increase air usage considerably and reduce the efficiency of the DirectFlo A large drop in pressure while the machine is operating can be an indication of an air leak Check the supply air inlet hose and the supply regulator for leaks This is a high pressure line so small leaks can cause the loss of large volumes of air If a leak is suspected within the ...

Page 65: ... During unit pressurization and depressurization the hose pinch will open and close This action weakens the hose at the squeeze point and leads to eventual hose failure Refer to Chapter 4 of this manual Maintenance for detailed information on reducing this type of failure If for some reason the pinch does not close tightly enough to completely seal the hose a very slight leak can rapidly wear thro...

Page 66: ...he hose see procedure above Replacing the Vent Pinch Assembly refer to Appendix B Figure 9 Prior to replacing the assembly check for proper pinch cylinder operation by performing the Set up and Test Procedure in Chapter 2 beginning with step 14 If any problems are encountered verify at least 80 psi is supplied to the cylinder from the air source when the unit is turned ON And the pressure to the c...

Page 67: ...orn nosepiece 1 Turn power OFF vent pressure from tank and disconnect air supply from unit 2 Reaching through the large hole in the blasters back panel with a 3 32 hex T wrench remove the 4 socket head cap screws Nose Valve Seat Assembly and its O ring 3 Remove the blue polymer nosepiece from the end of the Piston Rod by gently wiggling it back and forth and pulling it out toward you with a pair o...

Page 68: ...e piston on the air cylinder assembly can become eroded from the abrasive flow and should be paid special attention when inspecting internal parts The piston is part of the cylinder assembly and is replaced as a complete unit 7 Reassemble and install the PowderGate by reversing the above steps 8 Be sure the O ring is in the PowderGate base prior to installing the assembly into the machine PowderGa...

Page 69: ... allow the core to slide out Note the core s orientation the cross holes must be nearest the tank 9 Examine the edges and ring seat of the core They must be smooth and even If it has any scratches or roughness that can be felt with a fingernail replace the entire Modulator Housing Assembly PF2040 If neither the nose seat nor the core is worn reassemble the modulator housing assembly and skip to st...

Page 70: ...ter 5 Trouble Shooting and Repair Comco Inc 5 16 Issue Date January 2009 Figure 5 3 Modulator Assembly and Modulator Housing Assembly See illustration below PF2040 Modulator Housing Assembly part of Modulator Assembly above ...

Page 71: ...ps or bottoms out no high or low stop Replace the Regulator Assembly according to the following procedure Air Pressure Regulator Assembly Replacement Procedure 1 Turn Power OFF and depressurize unit 2 Remove the DirectFlo cover 4 screws 3 Disconnect the hoses from the regulator assembly You may want to label each air hose before removing 4 Remove the retaining nut from the front of the regulator 5...

Page 72: ...DirectFlo DF1400 Chapter 5 Trouble Shooting and Repair Comco Inc 5 18 Issue Date January 2009 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 73: ...hapter 6 Optional Equipment Comco Inc 6 1 Issue Date January 2009 Chapter 6 Optional Equipment and Manual Supplements In This Chapter Optional equipment available on your DirectFlo Operation and service of these options ...

Page 74: ...quipment Comco Inc 6 2 Issue Date January 2009 Splitters can be integrated with the DirectFlo to supply abrasive to multiple nozzles Additional information on splitters and multiple nozzle arrays is available in Chapter 3 page 11 Rev 07 15 ...

Page 75: ...DirectFlo DF1400 Chapter 6 Optional Equipment Comco Inc 6 3 Issue Date January 2009 Rev 07 15 ...

Page 76: ...cutting fluids or moisture such as on an automatic hypodermic needle grinder For these situations it is desirable to have a low pressure continuous stream of air flowing out through the nozzle preventing moisture from migrating up inside the tip Moisture in this area could cause the abrasive media to clump up and plug the nozzle tip Blasters equipped with the optional Constant Air Bleed provide th...

Page 77: ...DirectFlo DF1400 Chapter 6 Optional Equipment Comco Inc 6 5 Issue Date January 2009 Rev 07 15 ...

Page 78: ...227 Nipple 1 4 NPT Stainless Steel SP1359 Tubing Poly 5 32 OD Clear ST4232 Tee Male Run 5 32 T x 10 32 ST4028 Nipple 1 4 NPT Brass ST4238 Connector 5 32 T x 1 8 NPT ST4087 Elbow Street 1 8 NPT ST5010 Grommet ST4226 Tee 1 4 NPT Stainless Steel ST6204 Needle Valve For a complete Pneumatic Diagram of the blaster see Appendix B of this manual PNEUMATIC DIAGRAM PARTS DRAWING Rev 04 10 ...

Page 79: ... NOT TURN ON BLAST WHILE SETTING FLOW 3 After setting the air flow lock down the adjusting screw with the lock nut Service If the bleed air fails to flow out of the nozzle service may be necessary 1 Check the nozzle to make sure it is not clogged Does abrasive flow when the blast is on 2 Adjust for proper air flow as detailed above 3 Flow Control valve may be clogged with abrasive powder Flush out...

Page 80: ...DirectFlo DF1400 Chapter 6 Optional Equipment Comco Inc 6 8 Issue Date January 2009 THIS PAGE LEFT INTENTIONALLY BLANK ...

Page 81: ...DirectFlo DF1400 Appendix A Assemblies Components and Parts Comco Inc A 1 Issue Date January 2009 Appendix A Parts Lists for the DirectFlo DF1400 ...

Page 82: ...in Dowel 1 4 X 1 1 4 4 PF2429 3 b Bypass Tube Assy DF Std Tank 1 PF2445 Vent Pinch Assy 1 MB1050 2 Plunger Pinch 1 MB1282 Tube Pinch 1 PF1404 3 Inlet Valve Assy 1 ST6208 3 4 Valve Sol 2 Way 3 8P 115VAC 1 ST4146 Plug Quick Disconnect Coupling 1 ST6245 3 5 Valve Sol 3 Way 2 2mm 1 ST6246 2 Regulator 1 4 0 140 psi 1 ST6256 Valve Flow Control 1 PF2480 Cover Assy Tank 1 MB1145 Flapper Assembly 1 ST5023 ...

Page 83: ...4 1 Modulator Assy 115V 1 PF2040 Housing Modulator Assy 1 MB1294 Core Modulator 1 PF2199 Body Modulator DF PF 1 PF2050 Nose Assy Modulator 1 PF2042 Coupler Modulator 1 MB1310 7 2 Coil Modulator 115V 1 PF2443 Regulator Assy Main 1 PF2472 Regulator 3 8NPT 1 PF2210 Filter Assembly 1 ST6209 Valve Check 1 MB1560 Filter Check Valve Assy 1 PF2142 Powder Adj Assy High Flow 1 PF2148 Valve Needle RFC 1 4 P ...

Page 84: ... Block 1 ST2005 005 4 6 Fuse 220V 1A Time Delay 1 PF2402 Cover Chassis 1 ST2164 1 4 Recept Conn 4 Pin Sq Flange 1 ST2130 2 4 Power Inlet AC IE320 1 PF2414 Footswitch w cable 1 ST7716 1 4 5 Power Cord 1 ST7039 124 Resistor 120K 1 2W 5 1 ST4014 4 Union Blkhd 250Tx 250T Brs 1 MB1483 4 Quicknut 1 4 Poly Tubing 2 For reference only parts not sold individually 1 Extended Tank Model requires Powder Baske...

Page 85: ...sive Poly 12 ft PF2110 1 Nozzle 0 060 red 1 PF2110 3 Nozzle 0 080 red 1 PF2120 Sleeve Tube 3 ST5066 Funnel Abrasive 1 ST5114 Nut driver 1 4 1 ST7716 1 Power cord 1 ST5508 O ring nozzle 5 ST5518 Wrench 9 16 1 ST4209 Ferrule Set 3 8 Tubing 2 PF2090 Nose Assembly Nozzle 1 MB1653 Nosepiece PowderGate 1 1 The Accessory Parts kit for 230v machines is PF1408 2CE Power cord is ST7716 9 and two fuses are a...

Page 86: ...e Abrasive 375 Polyhose 30 ft PF2090 Nose Assy Nozzle 2 PF2120 Sleeve Tube 24 ST2005 005 Fuse 220V 500mA 1 ST2005 0315 Fuse 220V 3 15A 1 ST1289 Nut Hex for Cover Bolts 4 ST4014 Union Blkhd 1 ST4184 Connector 3 8 Tubing X 1 4 NPT SS 1 ST4209 Ferrule Set 3 8 Tubing 5 ST4159 Nut Tube 375 2 PF2139 O ring Replacement Kit 1 ST5161 O ring 489 ID 1 ST6209 Valve Check 1 ST6210 Regulator 1 ST6267 Filter Ele...

Page 87: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 1 Issue Date January 2009 Appendix B Drawings and Schematics for the DirectFlo DF1400 ...

Page 88: ... 5 P N PF1480 Tank Cover Assembly B 9 Figure 6 P N PF1409 Abrasive Tank Assembly B 10 Figure 7 P N PF2034 Modulator Assembly B 11 Figure 8 P N PF2406 Handpiece Abrasive Hose Assembly B 12 Figure 9 P N PF2445 Vent Pinch Assembly B 13 Figure 10 P N PF2450 PowderGate Assembly B 14 Figure 11 P N PF2443 Pressure Regulator Assembly B 15 Figure 12 P N PF2142 Powder Adjustment Assembly B 16 Figure 13 P N ...

Page 89: ...IGURE 1 FRONT VIEW MODEL DF1400 1 See individual Part Drawing for Part Numbers Item No Description Part No Item No Description Part No 1 2 3 4 Power Switch Regulator Assy Pressure Gage Powder Flow Ctl ST2045 PF2443 MB1407 1 PF2142 5 6 7 Tank Cover Abrasive Tank Handpiece Assy PF2480 1 PF2406 ...

Page 90: ...V Terminal Block is PF1490 Item No Description Part No Item No Description Part No 1 2 3 4 5 6 7 8 Modulator Assy Powder Adj Assy Abrasive Basket Nipple 1 4 NPTX6 0 Tank Orifice PowderGate Assy Conn 3 8T 1 4 NPT Power Inlet PF2034 2 PF2142 1 ST4223 MB1409 X PF2450 ST4184 ST2130 2 8 9 10 11 12 13 14 15 Conn Body 3 8x1 4 NPT Solenoid Valve Assy Quicknut Vent Pinch Assy Inlet Valve Assy Terminal Bloc...

Page 91: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 5 Issue Date January 2009 FIGURE 3 PNEUMATIC SCHEMATIC MODEL DF1400 ...

Page 92: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 6 Issue Date January 2009 FIGURE 4A ELECTRICAL SCHEMATIC MODEL DF1400 ...

Page 93: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 7 Issue Date January 2009 FIGURE 4B ELECTRICAL SCHEMATIC MODEL DF1400 2 ...

Page 94: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 8 Issue Date January 2009 FIGURE 4C COMPONENT DESIGNATIONS ...

Page 95: ... PF2480 TANK COVER ASSEMBLY Item No Description Part No Item No Description Part No 1 2 3 4 Scrw 4 40x 25 Washer 4 Flapper Assy O ring ø1 734 ID ST1030 ST1027 MB1145 ST5023 5 6 7 O ring ø5 859 ID O ring ø 296 ID Bushing Feedthru ST5495 ST5496 PF2055 These items are part of PF2139 O ring Replacement Kit ...

Page 96: ...T Elbow 3 8T x 1 4P Bracket Tank Bolt Washer Hardened Swing Bolt Tank Cover ST4029 ST4229 ST4236 ST4311 ST4235 ST4162 PF2027 ST1270 PF2079 9 10 11 12 13 14 15 15 16 Hex Nut 5 16 18 Brass Pin Dowel 1 4 x 1 1 4 Tee Street 1 4P Conn W Qknut 1 8NPT Conn Body 1 4 NPT Conn Body 1 8 FPT Bypass Tube Assy Bypass Tube Assy Tubing 1 4 OD Blue ST1289 ST5163 6 ST4138 MB1455 ST4184 2 ST4265 2 PF2498 3 PF2498 4 ...

Page 97: ...PF2034 AND PF2034 2 MODULATOR ASSEMBLY 1 The Modulator Housing is a Sub Assembly consisting of three parts typically replaced as one unit 2 230V Coil is MB1310 8 Item No Description Part No 1 2 3 4 Conn Male 3 8T x 1 4P Coupling Modulator Coil Modulator Modulator Housing 1 ST4038 PF2042 MB1310 7 2 PF2040 ...

Page 98: ... B 12 Issue Date January 2009 FIGURE 8 P N PF2406 HANDPIECE ABRASIVE HOSE ASSEMBLY Item No Description Part No 1 2 3 4 5 6 Tube Handpiece Nose Assy Nozzle Tube Abrasive Spring Compression Nut Ferrule Set Ferrule Set only PF2066 PF2090 PF2083 ST5552 ST4266 ST4209 ...

Page 99: ...hematics Comco Inc B 13 Issue Date January 2009 FIGURE 9 P N PF2445 VENT PINCH ASSEMBLY Item No Description Part No 1 2 3 4 5 Plunger Pinch Vent Breather 1 8P Elbow Male 1 8 Thd Cylinder DBL Spring Tube Pinch MB1050 2 ST4003 ST4224 ST6081 MB1282 ...

Page 100: ...y Ferrule Set Only ST4184 ST4184 2 ST4209 4 Connector Block Rear PF2193 3 5 Nose Valve Seat Assy 1 PF2189 2 6 O ring 2 014 ST5161 7 O ring 2 016 ST5067 8 Wiper Felt PF2442 9 O ring 2 019 ST5546 10 O ring 2 018 ST5031 11 Nosepiece MB1653 12 Air Cylinder Assy 2 PF2471 13 14 15 Fitting 5 32 OD Body Valve Adapter Cylinder ST4172 PF2434 PF2436 1 2 Includes a ST5161 O ring Includes a MB1653 Nose Piece ...

Page 101: ...No Item No Description Part No 1 2 3 4 5 6 Tee Street 1 4 NPT Elbow 3 8Tx1 4 NPT Elbow Street 1 8 P Regulator 3 8 NPT Elbow Street 1 4 P Elbow 1 4Tx1 8 NPT ST4138 ST4142 ST4004 PF2472 ST4143 ST4144 7 8 9 10 11 12 Check Valve 1 4 NPT Filter Assembly Replac Filter Elem Elbow 3 8Tx1 4 NPT Filter Check Valve Conn 5 32T x 1 8 P ST6209 PF2210 ST6267 ST4162 MB1560 ST4238 ...

Page 102: ... N PF2142 POWDER ADJUSTMENT ASSEMBLY 1 Not Part of this Assembly Item No Description Part No 1 2 3 4 5 6 7 8 Conn 3 8T x 1 4P Bushing 1 2 x 1 4P Filter In Line 1 2 20M Check Valve Elbow Street 1 4P Elbow 3 8T x 1 4P Valve Needle 1 4 P Knob Black 1 ST4038 ST4125 ST6232 ST6209 ST4143 ST4142 PF2148 ST5520 ...

Page 103: ...cription PF2085 Tee Street Modified ST4146 Plug Quick Disconnect ST4003 Vent Breather 1 8 MPT ST4249 Elbow 5 32 T X 1 4 NPT ST4005 Bushing 1 4 MPT X 1 8 FPT ST6091 Relief Valve Adj 1 8 NPT ST4025 Nipple Close Hex 1 4 NPT ST6208 3 2 Valve Sol 2 Way 115V ST4136 Elbow 3 8 T X 3 8 NPT ST6245 3 1 Valve Sol 3 Way 115V ST4141 Bushing 1 4 FPT x 3 8 MPT ST6256 Valve Flow Control Meter In ST4143 Elbow Stree...

Page 104: ...sue Date January 2009 FIGURE 14 P N PF1407 PF1407 2 POWDERGATE VALVE 1 230 VAC Valve 4 Way is ST6265 2 Item No Description Part No 1 2 3 4 5 Valve 4 Way 110VDC Muffler 10 32 Thd Elbow 10 32 Thd Elbow Male 10 32 Thd Conn Valve 40 Wires ST6265 1 ST6263 ST4198 ST4222 ST6268 ...

Page 105: ...MBLY Part No Length Description PF2227 1 PF2227 2 12 375 20 625 Abrasive Basket Assy Standard Abrasive Basket Assy Extended Item No Description Part No 1 2 O ring Tank Orifice 1 ST5504 MB1409 25 1 Tank Orifice size may be changed Refer to Chapter 3 of the Manual This item is part of PF2139 O ring Replacement Kit Rev 11 09 ...

Page 106: ...DirectFlo DF1400 Appendix B Drawings and Schematics Comco Inc B 20 Issue Date January 2009 THIS PAGE LEFT INTENTIONALLY BLANK ...

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