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Clemco ZERO Pulsar III-P, Руководство пользователя

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PULSAR

®

 III-P/III-PE and VI-P/VI-PE PRESSURE CABINETS 

Page 1

 

 

 

 

 

 

© 2019 CLEMCO INDUSTRIES CORP.  

  www.clemcoindustries.com  

  Manual No. 21527, Rev. I, 02/19

 

1.0 

INTRODUCTION 

 

1.1 

Scope of Manual

 

 

1.1.1

  These  instructions  cover  the  setup,  operation, 

maintenance, troubleshooting, and replacement parts for 
the following Pulsar

® 

Pressure Blast Cabinets: 

 

Pulsar III-P Conventional, (stand-up model)  

 

Pulsar III-PE Ergonomic, (sit-down model) 

 

Pulsar VI-P Conventional, (stand-up model) 

 

Pulsar VI-PE Ergonomic, (sit-down model) 

 

A separate owner’s manual, stock no. 20951, is provided 
for the Sentinel Media Metering Valve. 
 

1.1.2

  The  instructions  contain  important  information 

required for safe operation of the cabinets. Before using 
this  equipment,  all  personnel  associated  with  the  blast 
cabinet  operation  must  read  this  entire  manual  and  all 
accessory  manuals,  to  become  familiar  with  their 
operation, parts, and terminology. 
 

1.2 

Safety Alerts 

 

1.2.1 

Clemco uses safety alert signal words, based on 

ANSI  Z535.4-2011,  to  alert  the  user  of  a  potentially 
hazardous  situation  that  may  be  encountered  while 
operating this equipment. ANSI's definitions of the signal 
words are as follows: 

 
 

This is the safety alert symbol. It is 
used to alert you to potential physical 
injury hazards. Obey all safety 
messages that follow this symbol to 
avoid possible injury or death. 

 

 

NOTICE

 

Notice indicates information that is considered 
important, but not hazard-related, if not 
avoided, could result in property damage. 

 

 

 

 

CAUTION 

Caution indicates a hazardous situation that, if 
not avoided, could result in minor or moderate 
injury. 

 

 

 

 

WARNING 

Warning indicates a hazardous situation that, if 
not avoided, could result in death or serious 
injury. 

 

 

DANGER 

Danger indicates a hazardous situation that, if 
not avoided, will result in death or serious 
injury. 

 

1.3 

Table of Contents 

 

SUBJECT 

SECTION LOCATION 

 

INTRODUCTION  ........................................................ 1.0 

Scope of Manual  ......................................................... 1.1 
Safety Alerts  ............................................................... 1.2 
Table of Contents  ....................................................... 1.3 
General Description  .................................................... 1.4 
Theory of Operation  .................................................... 1.5 
Blast Machine and Controls  ....................................... 1.6 
Nozzle Options  ........................................................... 1.7 
Reclaimer Options  ...................................................... 1.8 
Metering Valve Options  .............................................. 1.9 
HEPA Filter  ............................................................... 1.10 
Blasting Media  .......................................................... 1.11 
Compressed-Air Requirements  ................................ 1.12 
Electrical Requirements  ........................................... 1.13 

 

INSTALLATION  ......................................................... 2.0 

General Installation Notes  .......................................... 2.1 
Connect Compressed-Air Supply Line  ....................... 2.2 
Ground the Cabinet  .................................................... 2.3 
Connect Electrical Service  ......................................... 2.4 

Standard single-phase wiring ................................ 2.4.1 
Optional three-phase wiring .................................. 2.4.2 

Set Air-Inlet Damper  ................................................... 2.5 
Final Assembly  ........................................................... 2.6 

 

FIELD INSTALLED ACCESSORIES  ......................... 3.0 

Aluminum Oxide (aggressive media) Kit  .................... 3.1 
Cabinet Curtains Installation  ...................................... 3.2 
Manometer  ................................................................. 3.3 
Reclaimer Differential-Pressure Gauge  ..................... 3.4 
Turntable with Workcar and Track  ............................. 3.5 
Dust-Collector Differential-Pressure Gauge ................ 3.6 
Armrest  ....................................................................... 3.7 

 

OPERATION  .............................................................. 4.0 

Season Filter Cartridge ............................................... 4.1 
Media Loading  ............................................................ 4.2 
Media Unloading  ......................................................... 4.3 
Loading and Unloading Parts  ..................................... 4.4 
Blasting Operation  ...................................................... 4.5 
Operation and Function of the Choke Valve ............... 4.6 
Blasting Technique  ..................................................... 4.7 
Stop Blasting  .............................................................. 4.8 
Pulsing (cleaning) Dust-Collector Cartridge  ............... 4.9 
Shutdown  .................................................................. 4.10 

 

ADJUSTMENTS  ......................................................... 5.0 

Blasting Pressure (pilot regulator)  .............................. 5.1 
Media Metering (media flow)  ...................................... 5.2 
Reclaimer Static Pressure  .......................................... 5.3 

 

Содержание ZERO Pulsar III-P

Страница 1: ...t 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 This equipment is only one component of a cabinet blastin...

Страница 2: ...t in property damage CAUTION Caution indicates a hazardous situation that if not avoided could result in minor or moderate injury WARNING Warning indicates a hazardous situation that if not avoided could result in death or serious injury DANGER Danger indicates a hazardous situation that if not avoided will result in death or serious injury 1 3 Table of Contents SUBJECT SECTION LOCATION INTRODUCTI...

Страница 3: ...ozzle 8 4 Media bridging 8 5 Media surge 8 6 Air only no media from nozzle 8 7 Neither media nor air comes out the nozzle 8 8 Blast machine does not pressurize 8 9 Blast machine does not depressurize or depressurizes too slowly 8 10 Heavy media flow 8 11 Media buildup in cabinet hopper media does not convey to reclaimer 8 12 Static shocks 8 13 Dust leaking from cabinet 8 14 Dust leaking from dust ...

Страница 4: ...zzle 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 Figure 1 Exhauster Blow Off Hose Blast Hose Compressed Air Filter Debris Screen Dust Collector Inlet Dust Collector Dust Container Dust Collector Hopper Access Door Pulse Reservoir Reclaimer...

Страница 5: ...r the ASME code voids the Clemco ASME certification 1 6 3 Do not exceed the maximum working pressure rating PSI of the blast machine The maximum pressure rating is stamped into the ASME nameplate which is welded to the side of the vessel WARNING Excessive compressed air pressure can cause a blast machine to rupture To prevent serious injury or death do not exceed the rated pressure of the blast ma...

Страница 6: ...te Several variables that affect the reclaimer cleaning rate include blast pressure media air mixture media friability contamination of parts being cleaned damper setting static pressure and dust collector filter loading differential pressure across the dust filter cartridge When using larger nozzles the maximum mesh size of media will be smaller than those that are normally recommended Using medi...

Страница 7: ...3 38 1 4 47 54 61 68 Figures are approximate and for reference only and they may vary for different working conditions Several variables including media flow and nozzle wear affect cfm consumption Figure 3 1 12 1 The size of the compressor required to operate the cabinet depends on the size of the nozzle and blasting pressure Unless otherwise specified cabinets are supplied with a 3 16 orifice noz...

Страница 8: ...r line before performing maintenance 2 2 2 Install an isolation valve at the compressed air source to enable depressurization for service Connect a 1 ID or larger air line from the air source to the air filter A smaller diameter hose may reduce blasting efficiency 2 3 Ground the Cabinet 2 3 1 To prevent static electricity buildup attach an external grounded wire from an earth ground to the groundi...

Страница 9: ...tation of the fan can easily be observed Proper rotation is indicated by the arrow on the top section exhauster housing of the power module The fan should rotate clockwise when viewed from the fan end of the motor To reverse rotation change the wires as noted on the motor plate WARNING Do not look into the reclaimer exhauster outlet while the paddle wheel is turning Injury to the eye or face can o...

Страница 10: ...el Insert a 10 self drilling screw with an 11 16 OD flat washer through the grommet holes Use a screw gun with a 5 16 socket to drill and thread the screws through the door s inner wall at each grommet 3 2 4 Ergo side extensions Position the curtain on the wall to be protected Use the curtain as a template and mark the top mounting point through the grommet Remove the curtain and drill a 187 3 16 ...

Страница 11: ... the inside and outside tracks are aligned that the hinged extension rest evenly on the support angles when the extension is lowered and that the table is level 3 5 5 Raise the track extension and then open and close the door to make sure they function correctly When certain the table and tracks are aligned and level and that the workcar moves smoothly on all tracks tighten the leveling pad lock n...

Страница 12: ...racket 3 7 3 Drill a 3 8 hole at both locations and mount the armrest using 5 16 cap screw washers and nuts Install the bolts from inside the cabinet to protect the threads from abrasion should the armrest need to be removed later 3 7 4 Match drill the remaining four bracket holes and install the remaining fasteners Figure 13 3 7 5 Loosen the fasteners on the slotted bracket and raise or lower the...

Страница 13: ...ging of media is required use a vacuum to remove media residue in the cabinet hopper and blast machine head 4 4 Loading and Unloading Parts 4 4 1 Parts must be free of oil water grease or other contaminants that will clump media or clog filters 4 4 2 Load and unload parts through either door WARNING Use solid fixturing to hold heavy parts in place Do not remove lift equipment until the part is ade...

Страница 14: ...gh the grate stop blasting immediately and retrieve it NOTICE To prevent rapid frosting of the view window install a view window cover lens per Section 7 4 and avoid pointing the blast nozzle toward the view window 4 6 Operation and Function of the Choke Valve Figure 14 4 6 1 Always fully open the choke valve while blasting open is when the handle is vertical and aligned with the piping as shown i...

Страница 15: ...may not seal 5 1 3 Pressure registers on the gauge only while blasting While holding the nozzle securely adjust air pressure at the pilot regulator located on the top left side of the cabinet 5 1 4 To adjust pressure unlock the knob by pulling it out as shown in Figure 15 and turn it clockwise to increase pressure or counterclockwise to decrease pressure Once operating pressure is set push the kno...

Страница 16: ...to 120 Mesh 6 7 Steel Shot S 110 to S 70 6 7 Refer to Section 1 11 for media limitations 5 3 4 As dust accumulates on the outer surface of the cartridge static pressure drops requiring additional pulsing of the cartridge as described in Section 6 2 6 or an increase in pulse pressure per Section 5 5 When pulsing no longer maintains the necessary static pressure readjust the damper 5 4 Door Interloc...

Страница 17: ...c pressure which is controlled by the outlet damper as noted in Section 5 3 Reclaimer pressure must be set before cabinet pressure 5 6 2 Using a manometer as noted in Section 5 7 and listed in Section 9 1 is the most accurate method of monitoring and adjusting cabinet pressure Following the instructions packed with the manometer start the exhauster and insert the needle into a glove and adjust pre...

Страница 18: ...OTE Readings must be taken with the cabinet doors open and with the exhauster running 5 7 8 To find the static pressure add the number of inches the fluid travels up one column to the inches the fluid travels down the other column Refer to the example in Figure 21 Figure 21 5 7 9 After taking the readings replace the needle protector Close the manometer valves and store the manometer in the origin...

Страница 19: ...n and empty it daily and when loading media Empty the screen more often if part blasted causes excessive debris Do not operate the machine without the screen in place oversized byproduct from blasting could plug the nozzle While the door is open inspect the door gasket for wear or damage Replace the gasket at the first sign of wear 6 1 3 Drain compressed air filter Empty the drain pail at least on...

Страница 20: ...y Note that a small amount of dust egress is normal for a short time before a new cartridge is seasoned 6 2 6 Additional cartridge pulsing The cartridge is pulsed each time the foot pedal is pressed or released Additional pulsing should be performed per the following instructions every eight hours or more often under dusty conditions to prevent clogging of the cartridge 1 Turn OFF exhauster 2 Hold...

Страница 21: ...at the first sign of wear per Section 7 10 6 5 2 Pop up seal Inspect the rubber pop up seal and replace at the first sign of wear drying or cracking per Section 7 11 7 0 SERVICE MAINTENANCE WARNING Prior to doing any maintenance or opening the dust collector the employer must meet required OSHA standards including but not limited to 29 CFR 1910 for Appropriate Respirator Protective Clothing Toxic ...

Страница 22: ...lens and remove the lens Inspect the gasket and replace it per Section 7 2 2 if it is compressed or otherwise damaged before centering the new diffuser smooth side up over the gasket 7 2 3 2 Set the light module on the diffuser and reattach the cover 7 2 4 LED light module replacement 7 2 4 1 Turn OFF electrical power and perform lockout and tagout procedure to power supply 7 2 4 2 Remove the ligh...

Страница 23: ...s carefully remove the adhesive backing making sure the adhesive remains on the lens and apply the lens to the clean dry inner surface of the view window When the cover lens becomes pitted or frosted replace it 7 5 View Window Replacement WARNING Do not use plate glass for replacement view windows Plate glass shatters on impact and can cause severe injury Use only genuine ZERO laminated replacemen...

Страница 24: ...rim around the window frame bolt slots as needed 7 7 Window Frame Removal Figure 27 7 7 1 Remove the two window frame nuts located on the upper edge of the window frame and swing the window frame open NOTE The window frame in Ergo models is not hinged it is held by four frame nuts 7 7 2 Remove the window to prevent breakage 7 7 3 Pivot the window frame up or down until tension is off the frame hin...

Страница 25: ...e cartridge straight down until it clears the support bracket A small amount of rocking may be necessary to loosen the gasket seal from the sealing surface 7 8 7 Clean all reusable parts especially around the cartridge sealing area Scrape off any residual gasket material from the sealing surface 7 8 8 Install the new cartridge Tighten the retaining nut until the cartridge cannot be moved by hand T...

Страница 26: ...ole ring rap the plate with a rubber mallet or similar tool to loosen it Remove the door gasket if it is cracked dry or otherwise damaged 7 10 4 If the gasket requires replacement use rubber based glue to adhere it to the inspection door plate Allow the adhesive to cure before bolting the plate onto the machine 7 10 5 Use a short pipe wrench to unscrew the pop up valve guide from the elbow by turn...

Страница 27: ... new wear plate from seating against the reclaimer wall or top 7 12 5 Angle the new wear plate into the reclaimer inlet and position it so the straight end is flush with the inlet Use locking pliers clamps or other means where needed to pry the wear plate against the side of the inlet and inner wall as shown in Figure 33 Make sure the leading edge of the wear plate is aligned with the reclaimer in...

Страница 28: ... inlet 7 13 11 The wall liner is held in place with self drill tap screws from the outside of the reclaimer remove the screws and lift the wall liner from the top of the reclaimer 7 13 12 Inner cone liner and cone ring liner are glued onto the inner cone Pull off the liners to remove them 7 13 13 Remove all old caulking and adhesive from the weldment Installation Note The numbers in parentheses sh...

Страница 29: ...and use worm clamps to temporarily clamp the liner to the tube Tack weld the bottom of the cylinder liner to the inner tube in three or four places Remove the clamps when the cylinder liner is secured 7 13 24 Apply caulking to the seam on the cylinder liner and between the cylinder liner and top liner 7 13 25 Apply caulking around the top edge of the wall liner and top inner edge on the inlet hous...

Страница 30: ...e putting the reclaimer into service 7 15 Sentinel Metering Valve 7 15 1 Refer to the Sentinel Media Metering Valve Owner s Manual No 20951 for service and replacement parts 8 0 TROUBLESHOOTING WARNING To avoid serious injury observe the following when troubleshooting Turn OFF the compressed air supply bleed the supply line and lockout and tagout the air supply If checking the controls requires ai...

Страница 31: ...bolt on baffle 8 3 Reduction in blast cleaning rate 8 3 1 Low media level reducing media flow Check media level and replenish or replace as needed per Section 4 2 8 3 2 Media air mixture out of adjustment Adjust metering valve per Section 5 2 8 3 3 Reduced air pressure This may be caused by the pressure regulator set too low a malfunctioning regulator a dirty filter element in the air filter parti...

Страница 32: ...Depressurize the air supply line Remove the tubing leading to either the media metering valve or diaphragm outlet valve Pressurize the air supply line Air should not exhaust from the tube adaptors Press the foot pedal air should exhaust at the tube adaptor Release the foot pedal air should stop exhausting from the tube adaptors If it operates accordingly the metering valve requires service If it d...

Страница 33: ...clogged Refer to Section 5 5 to adjust pulse pressure refer to Section 6 2 6 for additional cartridge pulsing 8 12 4 Hole worn in flex hose between cabinet hopper and reclaimer inlet or between the reclaimer outlet and dust collector inlet Inspect hoses and replace them as needed 8 12 5 Reclaimer door open DO NOT operate unless door is closed 8 12 6 Obstruction in flex hose Remove hoses and check ...

Страница 34: ...r should be heard as the cam follower rides off the lobe when the pedal is pressed and again when it is released If the cam follower is working correctly and there is no spurt of air when the pedal is pressed and released it is likely a problem with the 3 way valve replace the 3 way valve 8 16 5 Check the diaphragm pulse valve and actuator assembly Refer to Figure 37 8 16 5 1 Remove the pilot actu...

Страница 35: ...e tubing for a blockage and inspect the foot pedal per Sections 8 16 2 8 16 3 and 8 16 4 8 17 A steady stream of air is heard within the dust collector when the foot pedal is not pressed 8 17 1 Cam follower does not ride off the foot pedal lobe Inspect alignment per Section 8 16 8 17 2 Diaphragm in the diaphragm pulse valve may be ruptured Inspect the diaphragm 8 17 3 The 3 way valve on the diaphr...

Страница 36: ...hose 15012 Window cover lens pkg of 5 06190 Manometer kit flexible u tube 12528 HEPA Filter assembly top mount 22807 Automatic pulse kit 21773 Time delay door locks for both doors 24163 Armrest assembly includes mounting hardware 24900 Armrest replacement 24899 Anti fatigue floor mat 2 foot x 3 foot for front of cabinet 24744 Pass thru door with 15 inch square cut out Right door for Pulsar III 236...

Страница 37: ...E ergonomic 25088 for VI P conventional 23542 for VI PE ergonomic 25089 Rubber curtains black Individual for conventional models Back curtain for III P 14243 for VI P 14247 Front curtain for III P 14242 for VI P 14246 Door curtain 2 required for III P 14244 for VI P 14245 Rubber curtains white Rubber curtain set for Pulsar III 23541 for Pulsar VI 23542 Rubber hopper liner set black for III special...

Страница 38: ...9 4 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 14 ft required at each location 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...

Страница 39: ...ve right hand only Band clamp attachment 12711 Quick Change clampless attachment 28639 10 Clamp for clamp attached glove 11576 11 Grommet blow off hose 3 4 ID 11798 12 Door latch assembly 20064 13 Grommet 1 4 ID x 1 2 OD 12762 14 Motor exhauster 1 hp 1 ph standard 12314 1 hp 3 ph optional 12310 15 Paddle wheel Pulsar VI 19234 16 Motor plate Pulsar VI 20224 17 Air valve 3 way door interlock 12202 1...

Страница 40: ...phragm outlet valve complete 03371 1 Nipple 1 x close 01701 2 Diaphragm outlet valve 06149 3 Washer 1 4 lock 03117 4 Screw 1 4 x 1 cap 03053 5 Cap diaphragm outlet 03393 6 Body diaphragm outlet 06135 7 Bushing 1 1 4 x 1 01804 Figure 45 9 6 View Window Assembly Figure 46 Item Description Stock No 1 Window glass 12 5 x 19 5 laminated 12212 2 Gasket 5 16 x 3 4 applied to cabinet per foot 6 feet requi...

Страница 41: ...1 2 female swivel 15002 20 Hose end 1 2 barb x 3 8 male NPT 06369 21 Blow off nozzle 13116 22 Hose 1 2 ID air specify ft required 12472 23 Regulator 1 8 NPT pilot pressure 12715 24 Gauge 1 8 cbm pressure 01908 25 Fitting 1 8 NPT elbow x 1 8 barb 11733 26 Tee 1 4 brass 02025 27 Foot pedal with tubing 20194 28 Metering valve Sentinel for 50 mesh and finer media standard 21439 for media coarser than ...

Страница 42: ...in 22425 18 Check valve 1 swing 12187 19 Muffler 1 4 bronze 03988 20 Coupling 1 2 blast hose CQA 1 2 00599 21 Gasket coupling CQG pkg of 10 00850 22 Nozzle holder CHE 1 2 00577 23 Blast hose 1 2 x 25 ft Cut in half to make 2 lengths 23750 24 Nozzle tungsten carbide CT 2 1 8 orifice 01351 CT 3 3 16 orifice standard 01352 CT 4 1 4 orifice 01353 25 Hose assembly 1 x 42 exhaust 23916 26 Bushing 1 4 x ...

Страница 43: ...452 13 Eyebolt 3 8 NC 00430 14 U channel 3 8 1 foot required 04076 15 Baffle 600 modular 29524 16 Plug 1 4 NPT pipe 01950 Figure 49 9 10 Dust Collector Figure 50 Item Description Stock No Repair kit diaphragm pulse valve 21600 1 Valve 1 diaphragm pulse 19578 2 Valve 3 way 12202 3 Fitting 1 8 NPT straight x 1 8 barb 11732 4 Nipple 1 8 NPT hex 01962 5 Actuator air pilot 19123 6 Fitting 1 4 NPT strai...

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