Caviblaster 3040-E Operation & Maintenance Manual Download

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CAVIDYNE LLC

5077 Fruitville Rd., Suite

109-157 Sarasota, FL 34232

Phone: (352) 275-5319

Operation &

Maintenance

Manual

Model 3040-E

Summary of Contents for 3040-E

Page 1: ...CAVIDYNE LLC 5077 Fruitville Rd Suite 109 157 Sarasota FL 34232 Phone 352 275 5319 Operation Maintenance Manual Model 3040 E ...

Page 2: ...nnel This equipment generates high pressure water and is intended for underwater use only 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 ade...

Page 3: ...on 16 4 3 Initial Set Up 17 4 3 1 Connecting the Water Source 18 4 3 2 Priming the System Using the Feed Pump System 18 4 3 3 Water Supply Conditions 19 5 0 OPERATION 22 5 1 Preparing the CaviBlaster for Operation 22 5 2 Startup of the CaviBlaster 22 5 3 Normal Operation 23 5 4 Adjusting the CaviBlaster for Maximum Performance 24 5 5 Recommendations for Effective Results 26 6 0 MAINTENANCE 29 6 1 ...

Page 4: ...eatures 7 Figure 2 2 CaviBlaster 3040 E60 Control panel 8 Figure 4 1 Lifting Guidelines 14 Figure 4 2 Installation Guidelines 16 Figure 4 3 Gravity Feeding Source 18 Figure 5 1 Zero thrust gun Pressure Calibration 25 Figure 5 2 Zero thrust Gun Position for Best Results 27 Figure 6 1 Inspection Cleaning Water Filter Strainer 31 Figure 6 2 Zero Thrust Gun 32 This space intentionally left blank ...

Page 5: ...zle Operating Pressure 4 000 PSI 276 BAR Motor 100 HP 3 PHASE 480 Volts 60Hz 58 5 Amp Installation 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 Leng...

Page 6: ...ro thrust gun connecting high pressure hose and an electric motor powered high pressure pumping unit The zero 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 3040 E60 power unit is a complete plug and play system built into a self supporting frame that allow...

Page 7: ...Page 7 36 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 2 1 CaviBlaster 3040 E60 General Features ...

Page 8: ...Page 8 36 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 2 2 CaviBlaster 3040 E60 Control panel ...

Page 9: ...nventions 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 click on the section name or figure reference to jump to that section The words This sp...

Page 10: ... 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 11: ...should only 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 3 1 Personal Safety Operation of the CaviBlaster 3040 E60 underwater cleaning system must only be attempted by commercial divers or other personnel who have been trained in its use Appropriat...

Page 12: ...rating this equipment If the diver is not wearing a diving helmet hearing protection is 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...

Page 13: ...ce parts with those recommended by or supplied by CAVIDYNE LLC 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 may lead to catastrophic equipment failure and serious personal injury Use of guns or pressure noz...

Page 14: ...d immediately contact CAVIDYNE LLC and the shipping company If the unit will not be installed 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 fr...

Page 15: ...llations will require provisions for adequate motor 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 ...

Page 16: ...r to the OFF position 4 Turn the HPP motor switch SW1 to the OFF position 5 Turn the feed pump switch SW2 to the OFF position 6 Connect the power cable not provided for the unit to the power source Refer to Page 5 of this manual and consult local electric codes for cable power requirements 7 Confirm correct rotation of Feed Pump Unit Reverse power cable wiring to achieve correct rotation 8 Close a...

Page 17: ...e straight and at a slight downward angle from the inlet connection on the water connection panel with no humps in the hose so that trapping of air pockets and creating an air lock is minimized During the priming cycle the suction hose should always remain below the height of the inlet connection unless connecting with a positive pressure water source Note Assure that no air is trapped in the feed...

Page 18: ... to the power unit water inlet Figure 4 3 Gravity Feeding Source a Using the Feed Pump System Verify the main power switch HPP motor switch and feed pump motor are switched to OFF Ensure the E Stop button is Pushed In so that the power supply has been disconnected See 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 Figu...

Page 19: ... the power supply has been disconnected See Figure 2 2 Connect a hose minimum 1 1 2 diameter 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 ...

Page 20: ...sales cavidyne com or call 1 352 275 5319 EOS 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 21: ...h use 1 Inspect the CaviBlaster power unit electric power cord hoses JIC fittings and gun 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...

Page 22: ... helmet hearing protection is recommended CAVIDYNE LLC 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 Pull the gun trigger to the open or ON position See figure 5 3 10 The system is now ready to operate 5 3 Normal Operation Norma...

Page 23: ...n cause injury when the gun is out of the water ALWAYS keep the gun submerged when the pressure pump is running 5 4 Adjusting the CaviBlaster for Maximum Performance The pressure at the nozzle of the zero thrust gun has to be maintained within certain limits to achieve cavitation and for best performance results Using a calibration pressure gauge tool situated between the pressure hose and the Cav...

Page 24: ...les are pointed away from the diver s or operator s hands arms and body Start the power unit See Section 5 2 Pull the gun trigger to the open or ON position See Figure 5 3 Hold the gun tight and observe the calibration gauge See Figure 5 2 The power unit operator should turn the knob on top of the pressure regulating valve until pressure reads 4 000 psi 276 BAR on the calibration gauge at the Z T ...

Page 25: ...Page 25 36 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 5 1 Zero thrust gun Pressure Calibration ...

Page 26: ... is to hold the nozzle 2 5 inches 5 12 cm away from the surface to be cleaned and at a 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 clo...

Page 27: ...Page 27 36 For more information please email sales cavidyne com or call 1 352 275 5319 Figure 5 2 Zero thrust Gun Position for Best Results This space intentionally left blank ...

Page 28: ...source or if using gravity feed shut off the supply of water to the pressure pump 3 Turn 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...

Page 29: ...m all hoses prior to performing any service work Only replace parts with those supplied 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 Fail...

Page 30: ...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 valve is worn and should be replaced 3 The initial oil change is after 50 hou...

Page 31: ...onnection 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 the bowl CW onto the housing nut to hand tighten 7 Loosen and remove cap of main fil...

Page 32: ...hours place the gun in a container of clean fresh water Ensure the gun is completely submerged 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 a...

Page 33: ...See Figure 2 2 and place the open end of the clear hose into the antifreeze 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...

Page 34: ...air is moving across cooling fins Excessive dirt build up on motor clean motor Unbalanced voltage check voltage at all phases should 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 balanc...

Page 35: ...K CASE Check the pump seals for damage feeding water at greater than 50 psi 3 4 bar can force 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 asse...

Page 36: ...TER BAG 1 1 Inlet strainer cartridge 3260 02 1 1 Pump seal kit 04 KIT UD 139 1 1 Pump valve 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 Suit...

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