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Empire ProFormer Operating Instructions Manual

Cabinet system, pressure and suction
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• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Operating Instructions
for the
ProFormer
Cabinet System
TM
Pressure and Suction
2101 West Cabot Boulevard
Langhorne, PA 19047-1893
www.empire-airblast.com
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Summary of Contents for Empire ProFormer

  • Page 1 • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • Operating Instructions for the ProFormer Cabinet System Pressure and Suction...
  • Page 2 To order Empire replacement parts, contact your local authorized Empire distributor. For the name of your local distributor, call Empire Customer Service, 1-800-497-4543, or fax us at 215-752-9373, or e-mail us on our website www.empire-airblast.com and we will call you back.
  • Page 3 Empire Abrasive Equipment Company Operating Instructions for the ProFormer Cabinet System Suction and Pressure Empire Abrasive Equipment Company 10/06/06 Page 3...

  • Page 4: Table Of Contents

    1.0 Installation ......................6 1.1 Hand Tools Required ..................6 1.2 Preparing for Installation .................. 6 1.3 Getting Started....................6 1.4 Positioning the ProFormer System ..............6 1.5 Electrical Connections ..................7 1.6 Compressed Air Connection................10 1.7 Earth Ground....................11 1.8 Installation Check ..................

  • Page 5: Introduction

    Empire: The leader in air-blast technology. Empire specializes in the design and manufacture of air-blast equipment, and has continued as an industry leader of more than 50 years. Today, Empire produces the ™ most extensive line of air-blast products in the world. In addition to ProFormer ™...

  • Page 6: Installation

    Compressed air, earth ground, and electric power are all that need to be connected. The equipment must be placed on a ™ level surface. Do not install your ProFormer system on a floor subject to wet conditions.

  • Page 7: Electrical Connections

    The customer is responsible for providing appropriate disconnecting means adjacent to the equipment for each incoming power circuit. ™ The standard power supply for the ProFormer 600 CFM, 1 ½ HP system is 220- 240volts/60 cycle/single phase. Cabinets are also available pre-wired for the optional power supplies listed in section 8.0 Options and Accessories.
  • Page 8 Empire Abrasive Equipment Company Figure 2. Electrical Connection Locations The three-phase schematic shown in Figure 5 also appears on the back of the transformer/contactor electrical box cover. The 10 foot, 4-wire line cord is located above the cabinet light box. The single-phase schematic shown in Figure 4 also appears on the back of the light box cover.
  • Page 9 Empire Abrasive Equipment Company IMPORTANT Before connecting power, check that the voltage requirements of your ProFormer system are consistent with the voltage available at the installation site. Figure 4. 220-240 Volt Single-Phase Figure 5. Three-Phase Option Note: The transformer is not included with dual-source systems.

  • Page 10: Compressed Air Connection

    Empire Abrasive Equipment Company 1.6 Compressed Air Connection IMPORTANT To operate properly, your ProFormer system requires clean, dry air. Moisture or oil in the compressed air supply can contaminate the abrasive, which can prevent it from flowing freely and cause inefficient blasting. Though your...

  • Page 11: Earth Ground

    An Earth Ground stud is provided at the bottom right side on the enclosure back wall. ™ It is important to connect the ProFormer system to an Earth Ground to bleed off static electricity which may be generated while blasting. The Earth Ground may also reduce the discomfort an operator may experience when static electricity is discharged.

  • Page 12: Equipment Operation

    The suction system hopper should be filled to the bottom of the reclaimer screen. The pressure system vessel may be filled to the base of the sealing plunger. ™ Total media capacity by weight for the suction and pressure ProFormer system is shown for popular media in the table below.

  • Page 13: Start Up

    Empire Abrasive Equipment Company 2.2 Start Up Step 1: Check that all pipe and hose connections are tightly fastened and air tight. Check that all safety pins are properly installed in all quick couplings. Step 2: Perform maintenance checks per section 5.0 Maintenance.

  • Page 14: Dust Collector Cartridge Cleaning

    Empire Abrasive Equipment Company 2.4 Dust Collector Cartridge Cleaning IMPORTANT Never pulse clean the filters when the system is off. If dust is visible exiting the dust collector fan housing, stop blasting and service the collector. Pushbutton Control: During the blasting process, periodically check the Minihelic pressure gauge located above and to the right of the cabinet window.

  • Page 15: Equipment Adjustments

    Empire Abrasive Equipment Company 3.0 Equipment Adjustments 3.1 Suction System Media Flow Adjustment ™ The ProFormer suction blast system is equipped with the SAR-2 media regulator to control the flow of media to the suction blast gun. The regulator is located at the bottom of the storage hopper assembly inside the left component access door.

  • Page 16: Reclaimer Adjustment

    Unwanted dust and broken down media (fines) will be removed from the system and conveyed to the dust collector. See Figure 6. Empire’s reclaimer design has vertical slots with a solid tuning band. The original ™...
  • Page 17 Empire Abrasive Equipment Company NOTE As a new system is used, the filters become coated with dust, “seasoned” and the airflow in the recovery system will decease to the normal operating rate. This will affect previous reclaimer tuning band adjustments.
  • Page 18 Empire Abrasive Equipment Company Figure 6. Blast and Recovery Operation IMPORTANT An insufficient volume of secondary air entering the reclaimer will cause dust to accumulate with the “good” media in the storage hopper or pressure vessel. This accumulation leads to inefficient blasting. Conversely, too much secondary air will cause useful media to be carried to the dust collector and be wasted.

  • Page 19: Suggestions For Efficient Blasting

    The chart below lists the range of media recommended for each ProFormer Blast ™ System. Certain media, such as sand and slag, are not to be used in ProFormer cabinets, both for health reasons and because they pulverize on impact and cannot be recirculated.

  • Page 20: Blast Pattern

    DI-CARB or BORON nozzles to prevent premature wear. Empire strongly recommends using boron carbide nozzles when blasting with Aluminum oxide, which is the most abrasive media.

  • Page 21: Changing The Media

    Dispose of this waste properly. Suction System ™ Step 1: Turn the ProFormer system off. Open the left side equipment access door and locate the reclaimer, media storage hopper, and SAR-2 media regulator. Step 2: Using proper safety and protective equipment, place a container, such as a bucket, directly under the storage hopper and SAR-2 regulator.

  • Page 22: Pneumatic Controls

    Blast for 30 seconds to remove all media from the blast hose. ™ Step 5: Turn the ProFormer system off. Clean both reclaimer screens, readjust the Sure-Flo® grit valve, and close the reclaimer door. Dispose of all waste properly.
  • Page 23 Empire Abrasive Equipment Company The following schematic diagrams illustrate the pneumatic control circuits for suction systems (Figure 8A) and pressure systems (Figures 8B). For each system type, the cabinets are shown in blasting and non-blasting modes (shaded pipe is pressurized).
  • Page 24 Empire Abrasive Equipment Company Figure 8B. Page 24...
  • Page 25 Empire Abrasive Equipment Company The following drawings show media flow through a typical pressure system and are provided to help you understand how to maintain the media at the proper level. Pictured at right is a fully charged system with the vessel depressurized (no blasting).
  • Page 26 Empire Abrasive Equipment Company Thus, you can determine the amount of media in the vessel in either of two ways: (1) note how much continuous blast time you can achieve with a fully charged vessel and compare this with your current continuous blast time; or (2) stop blasting, open the reclaimer door, and visually determine the media level by looking into the top of the vessel.

  • Page 27: Helpful Hints For More Efficient Blasting

    2) Media selection 3) Operating procedures 4) Maintenance With the help of your Empire Distributor and/or Empire factory representative, you now own equipment that will properly meet your blasting requirements. You can select the proper media, operating procedures, and maintenance steps by following the recommendations in this manual.

  • Page 28: Maintenance

    Empire Abrasive Equipment Company 5.0 Maintenance 5.1 Daily Maintenance Step 1: Turn the cabinet snap switch on. Step 2: Remove the accumulated dust from the dust collector drum and the debris from the reclaimer screen. Step 3: Check the condition of the media. If the media is contaminated or broken down into dust, thoroughly clean the inside of the cabinet and recovery system and reload with new media.

  • Page 29: Weekly Maintenance

    DI-CARB or BORON nozzles to prevent premature wear. Empire strongly recommends using boron carbide nozzles when blasting with Aluminum oxide, which is the most abrasive media.

  • Page 30: Storage Or Temporary Non-Use

    Empire Abrasive Equipment Company Step 10: Check your spare parts inventory. Ensure that you have an adequate supply of replacement items. 5.3 Storage or Temporary Non-Use ™ If your ProFormer system will not be used for several days (or more), follow these...
  • Page 31 Empire Abrasive Equipment Company E) Replace the nozzle washer and nozzle. F) Return the blast pressure setting to normal. Step 2: Drain the general purpose filter. Close the drain valve. Page 31...

  • Page 32: Troubleshooting

    Empire Abrasive Equipment Company 6.0 Troubleshooting 6.1 Troubleshooting Chart Problem: Good media is being carried to the dust collector. Probable Cause Remedy New filters. Continue use until filter “cake” forms (approximately eight hours of operation). Tuning band is open too Adjust tuning band.
  • Page 33 Place part on metal surface, i.e. rubber mat. cabinet floor or turntable top. Low compressed air and Install Empire Anti Static Strap, part ambient humidity. 510411. Problem: There is blast air flow, but intermittent or no media flow. Probable Cause Remedy Blast air pressure too low.
  • Page 34 Empire Abrasive Equipment Company Damp media (If media Remove damp media from system and stays formed in a ball after replace with new, dry media. Check squeezed in the palm of compressed air supply filters. Do not the hand, it is too damp to blast wet or oily parts.

  • Page 35: Troubleshooting The Pneumatic Control Circuit

    Empire Abrasive Equipment Company 6.2 Troubleshooting the Pneumatic Control Circuit Hand Tools Required: The following tools are required to troubleshoot the pneumatic control circuit: • Pressure tester (P/N 140382) • 7/16” open end wrench • Flat-blade screwdriver Step-by-Step Procedures: Refer to the control circuits shown in Figures 15 and 16 and the troubleshooting procedures listed on the pages that follow.
  • Page 36 Empire Abrasive Equipment Company Problem: Switch is on. The lights and dust collector motor work, but blast will not activate. Probable Cause Test Remedy Step 1: Confirm that the If there is no air from the dust off The compressed air...
  • Page 37 Empire Abrasive Equipment Company Check the vent in the Confirms that the blast air valve blast air valve diaphragm diaphragm has failed. Repair or cover spring retainer nut replace the air valve. for leaking air. Step 8: Improper media. See section 4.1 Media Selection and There are media Use.

  • Page 38: Recommended Spare Parts

    Empire Abrasive Equipment Company 7.0 Recommended Spare Parts The following chart lists the parts you should maintain in inventory to ensure ™ continuous operation of your ProFormer system. Part No. Description Pressure Suction 501331 ¼” Di-carb nozzle (suction) or 501341 5/16”...

  • Page 39: Options And Accessories

    7. Harsh Media and Empire’s extended wear components increase service life in an Extended Wear aggressive or high-use environment. These components are...
  • Page 40 Empire Abrasive Equipment Company Category Options Description both of the operator’s hands free to manipulate work pieces. 9. Fine Media Kits Vibrating screen A vibrating screen in the reclaimer (plus an aerated media and (for pressure regulator for pressure systems) overcome flow problems associated...

  • Page 41: Proformer Tm Parts

    Empire Abrasive Equipment Company 9.0 ProFormer Parts 9.1 Reclaimer Item 600 CFM Description 140796 Reclaimer Body Assembly 766741 Removable top 770788 Door, reclaimer 524321 Gasket, reclaimer door 524371 Gasket, reclaimer to storage hopper 524342 Gasket, tuning band 767581 Tuning Band (steel part only) 551782 Bolt, 1/4"-20 x 2"...

  • Page 42: Pressure Blast Systems

    Empire Abrasive Equipment Company 9.2 Pressure Blast Systems Parts for Blast Hose Assembly – Standard 1/2” Part Model Item Description Number Number 504912 NA-2 Nozzle Adapter 505232 NC-1/2 Nozzle Coupling 524041 NW-5 Nozzle Washer, Ceramic nozzles, 5/8" ID (10 pack)
  • Page 43 Hose clamp, 2" (1 each end) Pressure Vessel Item Part Number Description 140802 Pressure vessel assembly, 1 cu. ft. 760813 Pressure vessel only, 1 cu. ft., ProFormer 760739 Hopper, 1-cubic foot, ProFormer 524371 Gasket, reclaimer to hopper) 523942 Sealing ring, rubber, 2-1/8" ID 510431...
  • Page 44 Empire Abrasive Equipment Company Sure-Flo Media Regulators Shipping Part Number Catalog Name Description Weight Manual Sure-Flo Media Regulator (grit valve) 290383 Manual 25 lbs. normally open, 9" clearance required Automatic Sure-Flo Media Regulator (grit valve) 290215 Automatic 30 lbs. normally closed, 9" clearance required...
  • Page 45 Empire Abrasive Equipment Company Automatic Sure-Flo Media Regulator Parts Part Item Description Nozzle Grit Comments Number 525451 Metering tube, 3/8" ID Small Fine Back out roller bolt 1/2" 525782 Metering tube, 1/2" ID Small-Med Fine-Med Back out roller bolt 1/2"...
  • Page 46 Empire Abrasive Equipment Company Spring & Diaphragm Assembly Detail WARNING Never attempt to disassemble the spring assembly in the automatic Sure-Flo. The spring is under tension and could cause injury to personnel. MG-78 Exhaust Valve Assembly & Options Part Item...
  • Page 47 Empire Abrasive Equipment Company 553982 Bolt, 3/8" -16 x 2" 552762 Lock washer, 3/8" 551122 Screws, seat, 1/4" -20 x 1/2" (pack of 3) 544512 Reducer bushing, 1-1/4" MPT x 1" FPT 520181 Hose Barb 1” Restrictor Parts 290218 Ceramic Restrictor kit (standard)

  • Page 48: Suction Blast Systems

    Empire Abrasive Equipment Company 9.3 Suction Blast Systems Components Part Item Description Number 760751 Hopper, 1 – gun suction 546332 Nipple, 1-1/4" NPT x 3" 524371 Gasket, reclaimer to hopper 520502 Hose clamp, 1/2" air hose (2 per hose) 523921 Grommet, air hose, 3/4"...
  • Page 49 Empire Abrasive Equipment Company SAR-2 Media Regulator Item Part Number Description 290156 SAR-2 Media Regulator, complete, 1-1/4" FPT 753351 Regulator body, SAR-2 510121 Plug, clean out 551042 Thumb screw, 1/4"-20 x 1" PARTS for MH-2 Guns Item Part Number Description...

  • Page 50: Dust Collector

    Empire Abrasive Equipment Company 9.4 Dust Collector Components Part Item Description Number 532523 Filter Assembly, (2) 516329 Diaphragm Valve, (2) 516328 Rebuild Kit, Diaphragm Valve 516104 Hose, 7” ID x 6” long 516106 Cover 515710 Gasket, Neoprene, 9-1/2” ID x 12” OD...

  • Page 51: Blowers (Fan & Motor)

    Empire Abrasive Equipment Company 9.5 Blowers (Fan & Motor) Blower Assemblies Standard CFM @ Part Number Horsepower Used with Notes Electrical 6" S.P. 140312 1-1/2 230/60/1 SEM-2 Note: Motor starters, contactors, interconnecting wiring and ducting not included. Components Item 1-1/2...

  • Page 52: Ducting/Hoses

    Empire Abrasive Equipment Company 9.6 Ducting/Hoses Conveying Hose Standard Systems – Suction or Pressure with Reclaimer & Collector Part Number Item Description Customer Factory Installed Upgrade 522351 Standard Duty Conveying Hose w/o clamps — (4" x 8’) (I.D. x length)

  • Page 53: Pipe Strings

    Empire Abrasive Equipment Company 9.7 Pipe Strings Pipe String Assemblies Part Number Pipe String Size Used With 140279 1/2" Suction – 1 gun 140280 1" Pressure, FaStrip Pipe String Mounting Hardware Part Number Quantity Description 564121 1/4" flat head bolt 552882 1/4"...

  • Page 54: Basic Cabinet Assembly

    Empire Abrasive Equipment Company 9.8 Basic Cabinet Assembly Components Both 3642 4652 Item Description Sizes Only Only 510401 — — Safety Glass, 14" x 22" ∆ 2† 524451 — — Gasket, window, 6' section 760291 — — Frame, window 523551 —...
  • Page 55 Recommended spare part – consumable wear item. † Essential component - to prevent downtime. †† For systems with optional equipment Specify length (per foot) WARNING Replace the window with Empire safety glass only. Failure to do so could result in serious injury. Page 55...

  • Page 56: Warranty

    7. Associated installation costs are excluded. 8. Freight costs for goods returned to Empire are to be assumed by the buyer unless the parts are determined defective by Empire. 9. Parts that are not supplied by Empire are not covered. Commercial components are warranted under term of the original manufacturer.

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