Related Manuals for Empire DUPONT E10020
Summary of Contents for Empire DUPONT E10020
- Page 1 INSTALLATION, OPERATION, MAINTENANCE MANUAL DUPONT E10020 SPCL36104-S SUCTION SYSTEM...
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Page 2: List Of Figures
Page 2 SPCL36104-S Suction System INSTALLATION, OPERATION, AND MAINTENANCE MANUAL for an SPCL36104-S SUCTION BLAST SYSTEM INTRODUCTION INSTALLATION INSTRUCTIONS FUNCTION OF COMPONENTS OPERATOR ELECTRIC CONTROL PANEL OPERATOR LOAD/UNLOAD STATION BLAST PRESSURE CONTROL BLAST COMPONENTS PNEUMATIC RECLAIM SYSTEM DUST COLLECTION COMPONENTS OPTIONAL COMPONENT FUNCTIONS POWERED PART HOLD DOWN ROLLERS NOZZLE OSCILLATOR... - Page 3 Please read these instructions carefully before installing and operating your system. If you have any questions or need further information, contact your local Empire distributor. For technical information please call the Empire TECHNICAL SERVICE GROUP at (215) 752-8800.
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Page 4: Installation Instructions
Page 4 SPCL36104-S Suction System INSTALLATION INSTRUCTIONS Reference drawings are listed in Section 12.0. Remove the system components from the skids and check for any damage which may have occurred during shipment. IF DAMAGE IS FOUND, IT IS THE RESPONSIBILITY OF THE CUSTOMER TO FILE AN INSURANCE CLAIM WITH THE SHIPPING COMPANY. - Page 5 Page 5 SPCL36104-S Suction System A main air shutoff valve with lockout has been provided. It is designed to be locked in the “OFF” position and bleed the air when closed. Close the main air shutoff valve. Make the compressed air connection to the Blast Cabinet pipe string on the back wall of the Cabinet. The supply line must be at least as large as the pipe string inlet.
- Page 6 Page 6 SPCL36104-S Suction System Run the system “dry” (without media) as described in Section 5.0. This step is important to 2.15 verify that the system is ready for media. 2.16 ABRASIVE MEDIA LOADING This system is designed to use aluminum oxide.. The amount of media needed to operate the system is approximately 5 cubic feet.
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Page 7: Function Of Components
Page 7 SPCL36104-S Suction System FUNCTION OF COMPONENTS This section gives a brief description and explains the operation of system components. OPERATOR ELECTRIC CONTROL PANEL 3.1.1 The red illuminated “EMERGENCY STOP” operator disengages the “Emergency Stop Relay” and removes power from all motion devices and their respective controls. When activated, the operator illuminates indicating its active state. - Page 8 Page 8 SPCL36104-S Suction System 3.1.12 The blue “E-STOP RESET” illuminated pushbutton is used to enable the Emergency Stop Relay (ESR) and apply power to all motion control components. This operator illuminates when the circuit is energized and in a normal operating mode. 3.1.13 The “BLAST ELAPSED TIME INDICATOR”...
- Page 9 Page 9 SPCL36104-S Suction System OPERATOR LOAD & UNLOAD STATIONS The operator opens the load door and slides the part over mandrel. When finished, operater removes the part. BLAST PRESSURE CONTROL 3.3.1 Locate the Pressure Regulator on the pipe string on the media storage hopper. Rotate the Pressure Regulator knob clockwise to increase, or counter clockwise to decrease the Blast Pressure.
- Page 10 Page 10 SPCL36104-S Suction System 3.4.3 Air Jet Connector The MH-3 air connector is fastened to the gun body by two socket head screws. Air jet position is fixed within the gun and is not adjustable. 3.4.4 Media Hose 3.4.4.1 (N/A) The 5/8” media hose enters through the handle of the MH-2 gun. A hose clamp nut and “O”...
- Page 11 Page 11 SPCL36104-S Suction System PNEUMATIC RECLAIM SYSTEM The Reclaim System consists of a pickup tube at the bottom of the Blast Cabinet cone, a media recovery duct, and a Reclaimer Assembly. The Blast Cabinet ventilation air is used to pneumatically convey spent media to the Reclaimer.
- Page 12 Dust Collector efficiencies are stated to show the normal range which might be expected and are not a guarantee of performance. If dust contains any toxic substances, secondary filtration of discharge air from the Blower may be required. Consult Empire if dust to be filtered is classified as other than “nuisance dust”.
- Page 13 Page 13 SPCL36104-S Suction System OPTIONAL COMPONENT FUNCTIONS Additional options may be supplied with the system. The following are available at time of manufacture. POWERED PART HOLD DOWN ROLLERS Pneumatic powered rollers hold the part down against the mandrel. The rollers come down on each end of the part to secure it during a blast cycle.
- Page 14 Page 14 SPCL36104-S Suction System (N/A) VIBRATORY CLASSIFIER (SCREENER) The purpose of a Vibratory Classifier is to have more control over the media that is reclaimed from the blast process and put back into the Storage Hopper. When media “breaks down” as a result of hitting the part being blasted, it may change shape (deform), and it may fracture, resulting in smaller particles of media.
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Page 15: System Start-Up Procedure
Page 15 SPCL36104-S Suction System SYSTEM START-UP PROCEDURE Follow this procedure to insure safe and continuous operation. Open the main air valve. Close the Main Electrical Disconnect switch and turn on the Blast Cabinet lights. Listen for the Automatic Bag Shake control to operate if your system has a Bag Type Dust Collector. NOTE: Reverse Pulse Cartridge Dust Collectors only clean while the Blower is in operation. -
Page 16: Daily Checks
Page 16 SPCL36104-S Suction System SYSTEM MAINTENANCE AND OPERATION CHECK Follow all the steps in this section to insure the system is ready for production. DAILY CHECKS Dump the Dust Collector waste. Inspect the waste for good media. If large quantities of usable media are present, refer to Section 9.7. - Page 17 Page 17 SPCL36104-S Suction System 6.11 Inspect all Oscillator limit switch arms for free movement and all split collar limit switch trippers for tightness and proper orientation. Repair and/or adjust before operating the system. 6.12 Replace all cracked or frosted windows, worn window curtains, and damaged door gaskets. Turn the “BLAST”...
- Page 18 Shut the system down. See Section 8.0. 7.11 Operator Interface Terminal (OIT) 7.11.1 When the system is powered up the “EMPIRE” screen will appear. Press the button on the touch screen or the “F1” soft-touch button below the screen to switch to the “MAIN MENU” screen.
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Page 19: Part Setup
Page 19 SPCL36104-S Suction System 7.11.2 The “MAIN” screen is now displayed, from here you can either adjust the “PART SETUP” parameters, go to the “PROCESS MONITOR” screen to see where in the cycle the system is currently at, switch to the “MAINTENANCE” screens to perform additional setup configurations or manual operate the machine, or check the overall “SYSTEM STATUS”... - Page 20 Page 20 SPCL36104-S Suction System Pressing the “MAINTENANCE” button or “F4” on the main screen brings up the “MAINTENANCE” menu screen. From here a choice of “ADDITIONAL SETUP PARAMETERS”, OSCILLATOR JOG SCREEN” , or “CYCLE TROUBLE SCREEN” can be made. In the event that communication problems arise or the operator interface program acts irratically, the “GO TO CONFIG SCREEN”...
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Page 21: System Status
Page 21 SPCL36104-S Suction System will not prevent a cycle from running but there is a possibility that the system will run out of media during the cycle and improper finish will be attained. 7.11.9 SYSTEM STATUS This screen allows a choice between looking at System faults or monitoring the status of the inputs and outputs of the PLC. -
Page 22: System Outputs
Page 22 SPCL36104-S Suction System 7.11.12 SYSTEM OUTPUTS This screen shows the current condition of all the outputs from the PLC. Green indicates that the output is on or active, red indicates that the ouput is off or inactive. - Page 23 Page 23 SPCL36104-S Suction System SEQUENCE OF SYSTEM SHUTDOWN Follow this procedure when blasting is complete, at the end of the day, or during extended idle time. Turn all selector switches to “OFF”. Press the red “SYSTEM OFF” pushbutton. Open the Main Electric Disconnect and close the main air supply valve. The main air supply valve will bleed off air from the system when closed.
- Page 24 Page 24 SPCL36104-S Suction System OPTIMUM PERFORMANCE ADJUSTMENTS This section will explain how to adjust components for optimum performance. MEDIA FLOW The Media Regulator is threaded onto a 1 1/4” pipe nipple under the Storage Hopper. The media hose is inserted into the 1 1/8” horizontal bore of the regulator. The thumbscrew is provided to apply slight pressure against the media hose to prevent movement.
- Page 25 Page 25 SPCL36104-S Suction System 9.7.2 Band Adjustment 9.7.2.1 Horizontal Slot Pattern Reclaimer and Band (refer to Figure 4) Rotate the band by sliding in one (1) direction until 1/16” of the opening is created between the band and Reclaimer slots. Place a pencil mark on the band and a corresponding reference mark on the Reclaimer body.
- Page 26 Many Cartridge Dust Collectors are shipped directly to the customer since they are not required to performance test the blast system at Empire. We have dedicated in-house Dust Collectors for use when testing new machines. Since they are shipped direct, the cartridges are totally CLEAN when first put into service.
- Page 27 Page 27 SPCL36104-S Suction System 9.8.5 “Delta-P” (Pressure Drop) Across the Cartridges A sufficiently thick coating of dust must build up on the cartridges to cause a pressure drop of 2” to 3” as read on the magnehelic or photohelic gages on the Dust Collector. Cartridges that are too clean do not filter well and may be damaged.
- Page 28 Page 28 SPCL36104-S Suction System NOZZLE DIAMETER AND AIR JET SIZE 9.9.1 The nozzle orifice size is normally twice the size of the air jet orifice size. EXAMPLE: A 5/32” air jet will be used with a 5/16” nozzle. A drill bit may be used to measure the orifice sizes. If the nozzle diameter increases by 1/16”...
- Page 29 Page 29 SPCL36104-S Suction System 10.0 OPERATIONAL PROBLEMS AND SOLUTIONS The following recommendations may help locate and solve system problems. 10.1 SYSTEM WILL NOT START Main Electric Disconnect open. Blown supply fuse. Blown control fuse. Tripped Blower Motor Starter and/or Blower Motor bad. 10.2 NO BLAST Main air supply valve off.
- Page 30 Page 30 SPCL36104-S Suction System 10.6 (N/A) 10.7 (N/A) 10.8 OSCILLATOR WILL NOT RUN Oscillator speed potentiometer set too slow. Door open or limit switch not made. Timer or Counter set to zero. Oscillator movement restricted. Internal adjustments on DC Motor Control Board (MIN, MAX, IR, CL, ACCEL, DECEL).
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Page 31: Suggested Spare Parts
Page 31 SPCL36104-S Suction System 11.0 SUGGESTED SPARE PARTS This list is recommended for “ON HAND” stock parts. Maintaining these parts in your stock will reduce down time for replacement of normal wear items. 11.1 EXPECTED WEAR ITEMS (for 1000 Hours of Blasting) Quantity Description Stock Number... - Page 32 Page 32 SPCL36104-S Suction System 11.2 SUGGESTED MAINTENANCE PARTS If continuous operation is critical, we recommend that these items be stocked. They may not be available for immediate delivery from Empire. Quantity Description Stock Number 25 Ft. Heavy-Duty Recovery Hose 515921 15 Ft.
- Page 33 Page 33 SPCL36104-S Suction System Compression Spring, 2 ½”lg 10020-58 Flange Bearing H571095 Crown Roller 97557-N22 Air Cylinder, Osc. 10020-54 Stilson Hold Down Roller 10020-55 DC Motor Controller 535003 Disconnect Fuse 532944 Motor Branch Fuse 532938 Transformer Primary Fuse 532231 DC Power Supply Fuse 532405 Control Fuse 10A...
- Page 34 Page 34 SPCL36104-S Suction System 12.0 REFERENCE DRAWINGS 12.1 STANDARD ASSEMBLIES Description Drawing No. System Bill of Materials B/M #10020 System Assembly D10020-A Cabinet Assembly D10020-C Roller Assembly D10020-R Oscillation Assembly D10020-N Blow Off Assembly B10020-B Suction Blast Gun Assembly B803378X Storage Hopper Assembly D806997X...
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Page 35: Limitations Of Warranty
All components located within the blast chamber are especially vulnerable to wear and should be inspected daily. Components that are determined by Empire to be defective within the warranty period will be replaced or repaired at the factory at NO CHARGE.