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CRYSTAL MARK SWAM-BLASTER LV-1, Operating And Maintenance Manual

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CRYSTAL MARK SWAM-BLASTER LV-1 Operating And Maintenance Manual Download Page 1

 

SWAM BLAST 

IS A REGISTERED TRADEMARK OF

 

CRYSTAL MARK, INC.

 

SWAM-BLASTER

 IS A TRADEMARK OF 

CRYSTAL MARK, INC.

 

     Micro Abrasive Sandblaster 

MODEL LV-1 

OPERATING AND MAINTENANCE MANUAL  

MANUAL NO. 6029 

REV. 6.0 01/07 

MANUFACTURED BY: 

CRYSTAL MARK, INC. 

A SWAN Technologies Corporation 

613 Justin Avenue, Glendale, CA 91201 USA 

(818) 240-7520 

•

 (800) 659-7926 

•

 FAX (818) 247-3574 

www.crystalmarkinc.com – [email protected] 

Summary of Contents for SWAM-BLASTER LV-1

Page 1: ...K INC Micro Abrasive Sandblaster MODEL LV 1 OPERATING AND MAINTENANCE MANUAL MANUAL NO 6029 REV 6 0 01 07 MANUFACTURED BY CRYSTAL MARK INC A SWAN Technologies Corporation 613 Justin Avenue Glendale CA 91201 USA 818 240 7520 800 659 7926 FAX 818 247 3574 www crystalmarkinc com sales crystalmarkinc com ...

Page 2: ...der Chamber Section 3 Operation 3 1 General 3 2 Operating Controls Indicators and Connectors 3 3 Operating Procedures Section 4 Service Instructions 4 1 General 4 2 Major Components and Their Theory of Operation 4 3 Periodic Service 4 4 Component Maintenance 4 5 Service Tips 4 6 Trouble Shooting Section 5 Reference Documents Electrical and Pneumatic Diagrams Illustrated Parts List Abrasive Flow Co...

Page 3: ...pecifications in this manual are current at the time of printing However because of CRYSTAL MARK INC policy of continual product improvement we reserve the right to make changes at any time without notice Please note that this manual applies to Model LV 1 It explains the equipment and their options Therefore you may find some explanations for equipment or options not installed on your SWAM BLASTER...

Page 4: ...t Applications for this unit include cutting abrading drilling deburring peening cleaning and texturing Consult CRYSTAL MARK INC or one of their authorized representatives for additional guidelines to assure safe and effective operation for your particular application 1 3 SPECIFICATIONS Power Requirements 115 VAC 60 Hz 1 Amp Optional 115 VAC 50 Hz 1 Amp Compressed Air Requirements Clean Dry Air CO...

Page 5: ... to the unit should be about 100 psi 689 kPa but can range from a minimum of 40 psi 276 kPa to a maximum of 140 psi 965 kPa The air source must deliver a minimum of 5 cfm at 80 psi 2 36 L s at 552 kPa Many plant compressed air lines are contaminated with moisture oil and dirt which are detrimental to the performance and operation of the unit Moisture filters and unloaders must be used Moisture fil...

Page 6: ...ence of electrical power Check the fuses If ok check the input power source and connections G Check Air Pressure Gauge reading Set Air Pressure Regulator as follows 1 Pull knob out and rotate to desired air pressure To obtain accurate reading cycle Footswitch on and off while adjusting air pressure 2 When air pressure is set push knob in H Actuate Footswitch or Flow Test Switch Air should flow thr...

Page 7: ...g Top Cover B Clean dust or debris from chamber s Top Cover and Plate C Rotate Top Cover knurled knob counterclockwise and remove Top Cover D Pour powder into chamber until its level is just below Bleed Off Fitting NOTE Make certain that no lint dirt or other foreign substances enter the chamber These can clog the orifice plate within the chamber E Clean Top Plate s seating surface Top Cover s bot...

Page 8: ...dicating electrical power is available No 3 POWDER FLOW KNOB Adjusts rheostat to obtain desired rate of powder flow No 4 POWDER FLOW VOLTMETER Indicates powder flow rate No 5 AIR PRESSURE GAUGE Indicates air pressure supplied to the Mixing Chamber No 6 AIR PRESSURE REGULATOR KNOB Adjusts Mixing Chamber s air pressure No 7 PINCH VALVE ADJUSTMENT REGULATOR KNOB Adjusts air pressure to Pinch Valve As...

Page 9: ...H Actuates vibrator and pinch valve causing flow of powder air mixture when depressed No 15 FOOTSWITCH CONNECTOR Connects Footswitch to unit No 16 INPUT AIR SUPPLY HOSE Connects external air supply to unit 1 4 18 NPT fitting is provided on end of hose No 17 RESET BUTTON Resets unit and Leak Detection System after pinch valve tube or powder air hose replacement No 18 RED INDICATOR LIGHT LEAK Indica...

Page 10: ...Figure 3 1 Operating Controls Indicators Connectors ...

Page 11: ...ng speed removal of material increases up to a certain nozzle tip distance Adjusting the powder flow using different pressure settings powders and nozzle sizes and types may also vary the cutting rate Etching or removing broad areas of metallized film or coatings can be accomplished by increasing the nozzle tip distance and diverting the stream at an acute angle C ADJUSTMENT OF POWDER FLOW Depress...

Page 12: ... the air pressure to the Abrasive Pinch Valve is shut off The pinch valve exhausts it s pressure that allows the plunger to be retracted by spring pressure and open the valve tube When the Footswitch or Flow Test Switch is released the pinch valve is again pressurized and the plunger closes or pinches the valve tube When the Power Switch is turned to the OFF position the Abrasive Pinch Valve remai...

Page 13: ...ly reset Pulling the ring can manually test the valve F AUXILIARY CHAMBER AND MIXING CHAMBER The Auxiliary Chamber and Mixing Chamber function together The purpose of the Auxiliary Chamber which is mounted above the Mixing Chamber is to store powder and keep the Mixing Chambers powder level constant This allows the Mixing Chamber to feed a constant amount of powder into the air stream Powder flow ...

Page 14: ...in the unit bleeds off the air pressure in the system and turns on the red LEAK indicator light After the worn pinch valve tube or hose is replaced turning on the Power Switch and depressing the Reset Switch resets the leak detector system PORT DELIVERING POWDER AIR MIXTURE TO NOZZLE AIR IN POWDER SIFTING THROUGH THE ORIFICE PLATE POWDER FROM AUXILARY CHAMBER BLEED POWDER LEVEL MIXING CHAMBER FIG ...

Page 15: ...units external surface with cloth moistened with a detergent based solution 4 4 COMPONENT MAINTENANCE Unless specified in the component maintenance instructions special instructions are not required to remove or replace components of the unit Use the component assembly drawings in Section 5 for reference CAUTION Prior to performing any maintenance on the unit turn the unit OFF and allow the system...

Page 16: ...lush the clogged tip This should be done in an exhaust chamber B PINCH VALVE TROUBLESHOOTING If a Pinch Valve fails to operate properly the Solenoid Valve the Pinch Valve itself faulty electrical connection defective hose or the Footswitch can cause the problem If the unit is installed in a machine the ON OFF flow control may be malfunctioning 1 Abrasive Pinch Valve Solenoid Valve and Footswitch L...

Page 17: ...g supplied to the Pinch Valve disassemble the Pinch Valve clean the parts and replace any that are worn or damaged 3 PINCH VALVE REGULATOR ADJUSTMENT The Pinch Valve Regulator adjustment is factory set to supply the correct air pressure to the pinch valve assemblies for normal operation Any decrease of pressure may create a leak through the nozzle tip Too much pressure will cause premature wear th...

Page 18: ...dware 4 Turn Power Switch ON depress Reset Switch and check for proper operation and air leaks E MAIN AIR SOLENOID VALVE The Main Air Solenoid Valve controls the flow of air into the unit The valve is either open providing airflow when the unit is ON or closed stopping the flow when the unit is OFF The valve is not field repairable Replace if it malfunctions F REGULATORS The unit is provided with ...

Page 19: ...ating back into the Check Valve The second Check Valve is located on the Abrasive Pinch Valve Solenoid This valves function is to keep the Abrasive Pinch Valve pressurized and pinched or closed when the Power Switch is turned to OFF The Check Valves are not field repairable If they fail replace The In Line Filter element can be replaced if clogged J VIBRATOR Each Vibrator Assembly is factory adjus...

Page 20: ...Firmly hold the chamber and vibrator and loosen the Mixing Chamber Cap Nut by turning it counter clockwise 3 Loosen the two large cleat cap screws and remove the one small cleat and its cap screw 4 Completely unscrew the Cap Nut from the chamber 5 The Mixing Chambers Cap can now be pulled up and the chamber can be moved out from underneath it A container should be readily available to place under ...

Page 21: ... loss of powder weight 3 A slightly heavier than normal flow is noticeable after the Auxiliary Chamber has been filled 4 An initial heavy burst of powder lasting for a fraction of a second may be experienced when the Footswitch is first actuated This momentary heavy mix is normal It is due to small amounts of settled powder in the line This may be corrected by changing the orifice plate size 5 Reu...

Page 22: ... of time may require replacement 5 With the system pressurized and the Abrasive Pinch Valve Tube closed leakage through the Abrasive Pinch Valve Tube should not exceed three bubbles per second with the nozzle tip immersed in water 6 With the system pressurized and the Bleed Off Pinch Valve Tube closed leakage through the Bleed Off Pinch Valve Tube should not exceed three bubbles per second with th...

Page 23: ...e section 4 4 A 2 POSSIBLE CAUSE Inoperative Abrasive Pinch Valve Solenoid Valve Valve should turn off air to Abrasive Pinch Valve when Footswitch or Flow Test Switch is depressed SERVICE Check solenoid operation see section 4 4 B 3 POSSIBLE CAUSE Defective Abrasive Pinch Valve SERVICE If pinch valve fails to retract when no pressure is present Repair or replace pinch valve assembly see Section 4 ...

Page 24: ...ostat see section 4 4 H 3 POSSIBLE CAUSE Vibrator magnetic coil burnt out SERVICE Replace Vibrator Assembly G PROBLEM No powder flow from Mixing Chamber POSSIBLE CAUSE Clogged Orifice Plate in Mixing Chamber SERVICE Remove disassemble and clean Mixing Chamber and Orifice Plate see Section 4 4 N H PROBLEM Powder spray from nozzle tip loses definition POSSIBLE CAUSE Worn nozzle tip SERVICE Replace n...

Page 25: ...Section V Page 1 SECTION 5 REFERENCE DOCUMENTS Electrical and Pneumatic Diagrams Assembly Drawings and Parts List ...

Page 26: ...Section V Page 2 ...

Page 27: ...Section V Page 3 ...

Page 28: ...Section V Page 4 ...

Page 29: ...Section V Page 5 ...

Page 30: ...Section V Page 6 ...

Page 31: ...Section V Page 7 ...

Page 32: ...20 23 BLEED OFF FITTING 3548 1 EXTRUDED CHANNEL 550 052 12 O RING 550 020 23 FITTING 3451 1 TOP COVER 3522 1 TOP PLATE CHAMBER 3506 1 3 8 24 NUT THIN CHAMBER BODY 3511 1 TIE ROD 3513 1 3 8 WASHER 3 8 24 NUT NYLOCK CHAMBER 3509 1 CHAMBER ASSY P N 3561 1 ...

Page 33: ...Section V Page 9 O RING 550 020 23 TOP COVER ASSY P N 3545 1 ...

Page 34: ...4511 1 MIXING CHAMBER CAP ASSY 3541 1 BASE CAP GASKET 3449 1 BASE CAP SCREW 3446 1 1688 1 Ø 045 X 8 ORIFICE 2400 1 Ø 026 X 8 ORIFICE 2400 3 Ø 026 X 16 ORIFICE LIST OF ORIFICE PLATES BASE CAP 3443 1 NIPPLE ASSY 4512 1 CAP GASKET 3448 1 LV 1 NIPPLE ASSY 4539 1 LV XV NIPPLE ASSY 4512 1 CAP NUT 3440 1 ...

Page 35: ...Section V Page 11 FITTING 3451 1 NUT SLEEVE ASSY 550 010 51 NIPPLE ASSY 3496 1 MIXING CHAMBER CAP 3447 1 MIXING CHAMBER CAP ASSY P N 3541 1 ...

Page 36: ...Section V Page 12 PRESSURE REGULATOR 550 050 12 1 8 NPT ELBOW W NUT SLEEVE 550 010 98 1 8 NPT MALE CONNECTOR 550 010 46 PINCH VALVE REGULATOR ASSY P N 3549 1 ...

Page 37: ...SSURE REGULATOR 550 050 21 1 4 NPT MALE CONNECTOR 550 010 20 1 4 NPT NIPPLE 550 010 24 1 4 NPT 90 STREET ELBOW 550 010 147 CHECK VALVE 550 038 49 1 4 NPT MALE ELBOW 550 010 55 ABRASIVE PINCH VALVE REGULATOR ASSY P N 4534 1 ...

Page 38: ...ge 14 EXH CYL 1 8 NPT MALE ELBOW 550 010 98 11 00 12 50 N O SOLENOID VALVE 500 017 10 1 8 NPT 90 STREET ELBOW 550 010 143 CHECK VALVE 550 038 38 1 8 NPT FEMALE ELBOW 550 010 139 PINCH VALVE SOLENOID ASSY P N 3551 1 ...

Page 39: ...0 011 14 1 4 NPT CONNECTOR 550 010 41 1 4 NPT STREET TEE 550 010 140 1 4 NPT MALE ELBOW 550 010 55 120 VAC SOLENOID VALVE 500 017 28 1 4 NPT STREET ELBOW 550 010 140 MALE ELBOW 550 010 39 MAIN AIR SOLENOID VALVE ASSY P N 4522 1 NOTE AIR HOSE AND END FITTING ARE SHOWN FOR REFERENCE ONLY AND ARE NOT INCLUDED WITH ASSY ...

Page 40: ...Section V Page 16 INLINE FILTER 550 059 29 REPLACEMENT FILTER ELEMENT 550 059 30 INSIDE 1 4 NPT FEMALE CONNECTOR 550 010 196 1 4 NPT CONNECTOR 550 010 20 INLINE FILTER ASSY P N 4186 2 ...

Page 41: ...Section V Page 17 PINCH VALVE COMPLETE ASSEMBLY 3405 1 ...

Page 42: ...INCH VALVE 3405 1 1 8 NPT MALE CONNECTOR 550 010 35 NIPPLE ASSY 2293 1 QUICK NUT 1721 1 FITTING 550 010 109 NIPPLE ASSY 2293 1 QUICK NUT 1721 1 PINCH VALVE ASSY P N 3406 1 NOTE O RING LUBRICATION PART NUMBER IS 550 017 1 ...

Page 43: ...NCH VALVE MIXING CHAMBER LV HOSE SUPPORT TUBE 1694 1 XV HOSE SUPPORT TUBE 4515 1 TEE 550 010 67 FILTER ASSY 3539 1 FITTING 3588 1 PRESSURE SENSOR SWITCH 500 010 56 LV HOSE SUPPORT TUBE 1694 1 XV HOSE SUPPORT TUBE 4515 1 MODEL LV 1 LEAK DETECTION SYSTEM ...

Page 44: ... 20 x 1 2 L SHCS 90357 1 4 LOCK WASHER CLEAT LARGE 3515 1 SHOCK MOUNT FRONT 550 041 9 SHOCK MOUNT REAR 550 041 8 90861 06 8 32 x 3 8 LONG VIBRATOR ASSEMBLY 3533 1 60HZ 3533 2 50HZ 90190 10 1 4 28 x 5 8 L SHCS 90357 1 4 LOCK WASHER CLEAT SMALL 3514 1 90177 24 1 4 20 x 1 1 2 L SHCS CHAMBER VIBRATOR ASSEMBLY MODEL LV 1 ...

Page 45: ...Section V Page 21 GRN WHT BLK NO NC C 4 BLK WHT GRN 3 2 1 ...

Page 46: ... 3590 1 NOZZLE CONNECTOR 10 32 THD 2296 1 NOZZLE ASSEMBLY 10 32 UNF MALE THREAD 3606 1 TUBING 3 32 I D 550 037 5 NOTE FOR TYPE OF NOZZLES AND PART NUMBERS AVAILABLE BY CRYSTAL MARK INC REFER TO THE ABRASIVE NOZZLE SELECTION CHART ...

Page 47: ...Section V Page 23 ABRASIVE NOZZLE CRYSTAL MARK INC REV 9 08 QUICK NUT ASSY 1721 1 ...

Page 48: ...Section V Page 24 ...

Page 49: ...Section VI Page 1 SECTION 6 REFERENCE DOCUMENTS Recommended Service Tools and Spare Parts Nozzles Powders Other ...

Page 50: ...Part Number Description 1 1694 1 Hose Support Tube Assy Long 1 1694 2 Hose Support Tube Assy Short 1 1721 1 Push On Tube Assy 2 2192 1 Top Block 2 2192 2 Bottom Block 2 2379 1 Plunger 1 2395 1 Carbide Nipple Assy 1 2400 1 Orifice Plate Assy 8 Holes x 026 Diameter 10 3245 1 Pinch Tube 2 2293 1 Carbide Nipple Assy 2 3448 1 Gasket Cap 2 3449 1 Gasket Base Cap 4 4539 1 Carbide Nipple Assy LV XV 2 500 ...

Page 51: ...Section VI Page 3 CRYSTAL MARK INC ...

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