Empire Pro-Finish 2636, Pro-Finish 6060, Pro-Finish 3648, Pro-Finish 60120, Pro-Finish 7272 Operating Instructions Manual
...
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
Operating Instructions
for the
Pro-Finish® Cabinet System
Pressure and Suction
• • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • • •
2101 West Cabot Boulevard
Langhorne, PA 19047-1893
www.empire-airblast.com
Empire Abrasive Equipment Company
Model Number: _______________________ Serial Number: ____________________________
Date of Purchase: ____________________ Date of Installation: _______________________
Distributor Purchased From:
Name: __________________________________________________________
Address: ________________________________________________________
Phone: _________________________________________________________
* * * * *
Manufactured by: EMPIRE ABRASIVE EQUIPMENT COMPANY
2101 West Cabot Boulevard
Langhorne, PA 19047-1893
Phone: 215-752-8800, Fax: 215-752-9373
Empire equipment should be properly maintained per the operating instructions. For
peak performance of your equipment, use only genuine Empire replacement parts;
accept no substitutes! The use of non-Empire parts will void the warranty.
PARTS AND SERVICE
1-800-497-4543
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.
Never use silica-based abrasives
in Empire blast systems.
CAUTION
Page 2
Empire Abrasive Equipment Company
Operating Instructions
for the
Pro-Finish® Cabinet System
Suction and Pressure
Empire Abrasive Equipment Company
3/24/08
Page 3
Empire Abrasive Equipment Company
Table of Contents
Table of Contents ................................................................................................4
Introduction........................................................................................................5
1.0 Preparing for Installation ..............................................................................6
1.1 Hand Tools Required ........................................................................................ 6
1.2 Step-by-Step Procedure .................................................................................... 6
2.0 Installation .................................................................................................10
2.1 Installing the Optional Dust Collector ............................................................. 10
2.2 Installing the System...................................................................................... 11
2.3 Electrical Connections.................................................................................... 11
2.4 Installing the Compressed Air Supply ............................................................. 12
3.0 General Equipment Operation .....................................................................13
3.1 Media Selection and Use................................................................................. 13
3.2 Media Loading................................................................................................ 15
3.3 Pneumatic Controls........................................................................................ 15
3.4 Equipment Start-up ....................................................................................... 18
3.5 Equipment Shut-down ................................................................................... 19
3.6 Equipment Adjustments................................................................................. 20
3.7 Helpful Hints for More Efficient Blasting ......................................................... 23
4.0 Maintenance ...............................................................................................24
4.1 Daily Maintenance.......................................................................................... 24
4.2 Weekly Maintenance....................................................................................... 27
4.3 Storage or Temporary Non-Use ....................................................................... 28
5.0 Troubleshooting ..........................................................................................29
5.1 Troubleshooting Chart.................................................................................... 29
5.2 Troubleshooting the Pneumatic Control Circuit............................................... 32
6.0 Recommended Spare Parts ..........................................................................36
7.0 Options and Accessories..............................................................................37
®
8.0 Pro-Finish
8.1 Reclaimers ..................................................................................................... 39
8.2 Pressure Blast Systems .................................................................................. 40
8.3 Suction Blast Systems.................................................................................... 42
8.4 Dust Collectors............................................................................................... 44
8.5 Blowers (Fan & Motor) .................................................................................... 47
8.6 Ducting/Hoses ............................................................................................... 48
8.7 Pipe Strings.................................................................................................... 50
8.8 Pressure Blast Systems .................................................................................. 51
8.9 Basic Cabinet Assembly ................................................................................. 55
9.0 Warranty .....................................................................................................57
Parts .........................................................................................39
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Empire Abrasive Equipment Company
Introduction
®
Congratulations on your selection of the Pro-Finish
Cabinet System from Empire
Abrasive Equipment Company. This manual is provided to assist you with the
®
unpacking, assembly, use, and maintenance of your Pro-Finish
Cabinet System.
Please read this manual carefully and keep it in the handy plastic pouch attached to
your system for future reference. If you have any questions about the operation or
maintenance of your equipment, contact your Empire distributor.
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 Pro-Finish
systems, our product line includes ProFormer Cabinets, ECON-O-FINISH™ Cabinets,
Modified Systems, Automated Blast Systems, Blast Rooms, and SuperBlast™ Portable
Blasters.
Empire Abrasive Equipment Company’s reputation as a leader in air-blast technology
is the result of meeting our customer’s demand for quality equipment and systems
that deliver increased productivity. We support our equipment with training, service,
and testing programs. When you need advice, assistance, or equipment on short
notice, our national network of distributors assures that help is nearby.
Figure 1. Pro-Finish
Page 5
®
Cabinet System
Empire Abrasive Equipment Company
1.0 Preparing for Installation
1.1 Hand Tools Required
The following tools are recommended for the installation of your Pro-Finish
system:
• 7/16” wrench or socket
• 6” adjustable wrench
• 9/16” wrench or socket
• medium flat-blade screwdriver
• 14” Pipe wrenches
• medium Phillips head screwdriver
• Channel Lock Pliers
1.2 Step-by-Step Procedure
Step 1: Unwrap and remove cabinet
and the components from the pallet.
Step 2: Most cabinet systems are
shipped with the reclaimer mounted to
the cabinet. If your system was
shipped with the reclaimer NOT
installed, install the reclaimer as
follows:
a. Lift the reclaimer assembly and
set in place against the rear of
the cabinet so that the slots in
the reclaimer bracket set down
on the “Z-strip”.
b. Push the reclaimer assembly up
against the rear of the cabinet so
that the mounting bolts
protruding from the rear wall of
the cabinet are inserted into the
keyhole slots in the bracket. See
Figure 2.
Step 3: With the reclaimer in position,
tighten the bolts.
Figure 2. Reclaimer Mounting
Step 4: Attach one end of the conveying
hose to the cabinet hose adapter.
Attach the other end of the hose to the
reclaimer inlet. See Figure 3. Use
supplied hose clamp to make
connections airtight.
®
Cabinet
Page 6
Figure 3. Conveying Hose
Installation or Assembly
Steps 5 through 12 apply to pressure
systems only. (Suction systems are
not equipped with a pressure vessel.)
Step 5: Move the pressure vessel into
position as shown in Figure 4.
Figure 4. Pressure Vessel Installation
Step 6: Adjust the leveling bolts on the
pressure vessel legs so that the weight
of the assembly is evenly distributed on
the floor and the hopper flange mates
with the pressure vessel.
Step 7: Install and tighten the six bolts
connecting the storage hopper flange to
the top of the pressure vessel.
Step 8: Connect the quick coupling
ends of the air hose / tubing harness
and to the 1” pipe string on the front of
the cabinet and on the vessel. See
Figure 5.
Figure 5. Air Hose Assembly to Pipe
String Assembly
Step 9: Install the safety pin through
the holes in both halves of each quick
coupling. See Figure 5.
Step 10: Connect the harness ¼” O.D.
control tubing to the exhaust valve and
air valve fittings as shown in Figure 5.
Making sure the connection is tight.
Step 11: Connect the 1” exhaust hose
from the MG-78 exhaust valve to the
hose barb located at the reclaimer inlet.
Step 12: Connect the blast hose quick
coupling as shown in Figure 6 to the
tank coupling below the Sure-Flo Media
Regulator. Install the safety pin.
WARNING
Be sure to insert the safety pins into
the two halves of each quick
coupling to lock them together.
Figure 6. Hose/Coupling Connection
Steps 13 and 18 apply to singlephase systems only.
If your system includes a dust collector,
make the electrical connection between
the fan motor and the cabinet electrical
control box as follows:
WARNING
Be sure that the cabinet supply cord
is disconnected before you start this
procedure.
Step 13: Remove the four screws from
the corners of the control box cover.
Step 14: Slide out the terminal strip
plate as shown in Figure 7.
Figure 7. Terminal Strip
Step 15: Insert the free end of the fan
motor cord into the strain relief on the
top of the electrical box, as shown in
Figure 8.
Figure 8. Strain Relief
Step 16: Pull about 16 inches of cord
into the electrical box.
Step 17: Notice that the fan motor cord
wires are numbered. Connect each
wire to the terminal of the same
number.
Step 18: Replace the terminal strip
plate and control box cover. Tighten the
strain relief where the connecting cord
enters the control box.
The single phase electrical schematics
shown in Figure 9 and Figure 10 also
appear on the back of the control box
cover.
Consult the schematic that applies to
the specific type of electrical power that
will be supplied to the cabinet. Your
power supply must match the label
power supply of the cabinet and dust
collector fan motor.
Figure 9 and Figure 10.
Empire Abrasive Equipment Company
Step 19: If your system has a fan and
dust bag, fasten the dust bag to the fan
outlet and secure with the clamp
provided.
Step 20: Install the dust hose between
the reclaimer outlet and the dust
Step 21: Secure the hose ends with the
clamps provided.
Step 22: Connect your system to
utilities as described in the Installation
section following.
collector inlet.
2.0 Installation
®
Your Pro-Finish
packages. All equipment must be well grounded and mounted on a level surface. DO
NOT install your Pro-Finish
to wet conditions.
All electrical connections to the Pro-Finish® cabinet should be made by a
qualified electrician and must adhere to the codes, standards, and procedures
specified by the authority having jurisdiction.
The customer is responsible for providing appropriate disconnecting means
adjacent to the equipment for each incoming power circuit.
system may arrive fully assembled or in easily assembled modular
®
system on a wooden floor, a rubber mat, or a floor subject
IMPORTANT
2.1 Installing the Optional Dust Collector
If your system includes a dust collector,
you should install it before your install
the cabinet, because in many
instances, the dust collector is located
behind the cabinet. Install the dust
collector as follows:
Step 1: Place the dust collector on a
level surface behind or adjacent to your
®
Pro-Finish
Cabinet location.
Step 2: Be sure the access door and
pneumatic shaker control on the dust
collector are easily accessible and the
dust hose inlet is directed toward the
cabinet.
Step 3: Allow enough space for the
cabinet doors to open freely. Also allow
enough room to remove the dust from
the dust collector hopper.
Step 4: Stabilize the dust collector by
adjusting its leveling bolts to
compensate for any unevenness in the
supporting floor.
Step 5: A separate ¼” air line is
supplied for the dust collector shaker
mechanism. Attach the free end of this
air line to the dust collector compressed
air inlet connection.
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Empire Abrasive Equipment Company
2.2 Installing the System
Step 1: Place the cabinet on a level
surface. Ensure that there is enough
space around the system for easy
access to components. There should be
enough space for work pieces to be
easily loaded and unloaded through the
cabinet doors.
2.3 Electrical Connections
The standard power supply for the 400
CFM (1 HP) systems is 115-volts/60
cycle/single phase. The standard
electrical supply for 600 CFM (1 ½ HP)
and 900 CFM (2 HP) systems is 230volts/60cycle/single phase. Cabinets
are also available prewired for the
optional power supplies listed in Section
7.0 Options and Accessories. Standard
single-phase systems are supplied with
a line cord (except for systems delivered
to Canada).
SINGLE-PHASE SINGLE SOURCE
SOURCE MOTOR CURRENT
% 110-120V/60HZ 1 HP 19.0 A
220-240V/60HZ 1 HP 11.0 A
110-120V/50HZ 1 HP 22.2 A
220-240V/50HZ 1 HP 12.6 A
110-120V/60HZ 1 ½ HP 23.0 A
# 220-240V/60HZ 1 ½ HP 13.0 A
220-240V/50HZ 1 ½ HP 15.0 A
110-120V/60HZ 2 HP 27.0 A
@ 220-240V/60HZ 2 HP 15.0 A
220-240V/50HZ 2 HP 17.4 A
SOURCE MOTOR CURRENT
208V/60HZ 1 HP 7.2 A
220-240V/60HZ 1 HP 6.3 A
440-480V/60HZ 1 HP 3.1 A
550-600V/60HZ 1 HP 2.5 A
380/50HZ 1 HP 3.0 A
208V/60HZ 1 ½ HP 9.3 A
220-240V/60HZ 1 ½ HP 8.1 A
440-480V/60HZ 1 ½ HP 4.0 A
550-600V/60HZ 1 ½ HP 3.2 A
380V/50HZ 1 ½ HP 3.9 A
208V/60HZ 2 HP 10.2 A
220-240V/60HZ 2 HP 8.9 A
440-480V/60HZ 2 HP 4.4 A
550-600V/60HZ 2 HP 3.5 A
380V/50HZ 2 HP 4.7 A
208V/60HZ 5 HP 19.9 A
+ 220-240V/60HZ 5 HP 17.3 A
440-480V/60HZ 5 HP 8.6 A
550-600V/60HZ 5 HP 3.9 A
THREE-PHASE SINGLE SOURCE
Step 2: Stabilize the cabinet by
adjusting its leveling bolts to
compensate for any unevenness in the
supporting floor.
380V/50HZ 5 HP 9.5 A
If your system is designed for threephase power, make the electrical
connections as shown in Figure 11.
For both single-phase and three-phase
systems, cabinets equipped with any of
the standard electrical supplies require
a minimum 20 AMP service and
minimum 12 gauge copper wire.
THREE-PHASE DUAL SOURCE
SOURCE MOTOR CURRENT
208V/60HZ 1 HP 4.8 A
220-240V/60HZ 1 HP 4.2 A
440-480V/60HZ 1 HP 2.1 A
550-600V/60HZ 1 HP 1.7 A
380/50HZ 1 HP 1.7 A
208V/60HZ 1 ½ HP 6.9 A
220-240V/60HZ 1 ½ HP 6.0 A
440-480V/60HZ 1 ½ HP 3.0 A
550-600V/60HZ 1 ½ HP 2.4 A
380V/50HZ 1 ½ HP 2.6 A
208V/60HZ 2 HP 7.8 A
220-240V/60HZ 2 HP 6.8 A
440-480V/60HZ 2 HP 3.4 A
550-600V/60HZ 2 HP 2.7 A
380V/50HZ 2 HP 3.4 A
208V/60HZ 5 HP 17.5 A
220-240V/60HZ 5 HP 15.2 A
440-480V/60HZ 5 HP 7.6 A
550-600V/60HZ 5 HP 6.1 A
380V/50HZ 5 HP 8.2 A
NOTE
The approximate single-phase
current draw for all dual source
systems is 3 amps at 110-120 VAC.
% = 400 CFM (-4)
# = 600 CFM (-6)
@ = 900 CFM (-9)
+ = 1200 CFM (-12)
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Empire Abrasive Equipment Company
Figure 11. Three-Phase Schematic Diagram
2.4 Installing the Compressed Air Supply
Step 1: Using the following two charts
to determine the proper air volume
®
needed for your Pro-Finish
system.
The volume of air required for efficient
operation of your system depends on
AIR REQUIREMENTS (SCFM) FOR SUCTION BLAST
40 psi 60 psi 80 psi 100 psi
¼” nozzle, 1/8” air jet 12 17 21 26
5/16” nozzle*,5/32” air jet 19 27 34 42
7/16” nozzle, 7/32” air jet 38 52 66 80
* Standard nozzle
the size of the nozzle you are using and
the desired blast pressure. The chart
lists the minimum air requirements in
SCFM for various nozzles and
pressures.
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Empire Abrasive Equipment Company
AIR REQUIREMENTS (SCFM) FOR PRESSURE BLAST
40 psi 60 psi 80 psi 100 psi
1/8” nozzle 10 14 17 20
3/16” nozzle* 22 30 38 45
¼” nozzle 41 54 68 81
* Standard nozzle
Step 2: Use the chart below to
determine the size of the air line needed
for your cabinet. Even when the
compressor is properly sized, the air
line that connects it to your cabinet
must be large enough to avoid a large
pressure drop, which can cause
inefficient blasting.
Example: Your systems includes:
(a) A 125 foot long air line which
requires a 1” line (according to
the table).
(b) An air volume of 80 CFM, which
requires a 1-1/4” line size
Choose the larger line size (1-1/4”).
Line Size (in) Length of Air Line (ft) Air Volume (SCFM)
¾ Up to 95 13 to 38
1 95 to 190 38 to 59
1-1/4 190 to 350 59 to 85
IMPORTANT
To operate properly, your Pro-Finish® 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
system is equipped with a general purpose filter to remove small amounts of
condensed water and oil from compressed air supply, this filter is not designed
to clean grossly contaminated air.
3.0 General Equipment Operation
3.1 Media Selection and Use
Proper media selection strongly
influences the efficiency of your
blasting operation. Your choice of
media depends on the kind of job to be
done (cleaning, deburring,
smoothing sharp edges, paint removal,
preparation for coatings, etc.) The size
of the media depends on the results
you need.
Fine media results in more impacts per
second over a given area. Therefore,
fine media is preferred for easy blasting
jobs, such as the removal of light rust
from steel.
Large media results in fewer impacts,
but each impact has more force, so that
large media is more suitable for difficult
jobs, such as removal of mill scale.
Page 13
Sometimes large and find media may be
combined for optimum results.
The chart below lists the range of media
®
recommended for each Pro-Finish
Blast System. Certain media, such as
sand and slag, are not to be used in Pro-
®
Finish
cabinets, both for health
reasons and because they pulverize on
impact and cannot be recirculated.
Media Type
Media Size
Suction
Pressure
R – Recommended. * Recommended optional vibrating screen for mesh sizes 200 to 300 or when high humidity is a problem.
NR – Not Recommended. ** Recommended optional vibrating screen and aerated media regulator for mesh sizes 200 to 300.
W/Reclaimer R R* R R* NR R NR R R
W/O
Reclaimer
W/Reclaimer R R** R R** NR R NR R R
W/O
Reclaimer
Aluminum Oxide
or
Garnet
46 to
80
Mesh
R NR NR NR R R R R NR
R NR NR NR R R R R NR
100 to
300
Mesh
Glass Beads Steel Grit Steel Shot
25 to
180
Mesh
200 to
300
Mesh
G-16
to
G-50
G-80
to
G-200
S-390
to
S-170
S-110
to
S-70
Walnut
Shells
or
Plastic
Any
Size
Spherical media, such as glass beads,
are used for general purpose cleaning
and finishing where a satin-like finish
is desired with little dimensional
change. Glass beads are effective when
used with pressures in the 20 to 60 PSI
range. Above 60 PSI, excessive bead
breakdown will occur.
Angular aggressive media, such as
aluminum oxide, steel grit, and garnet
generally provide faster cleaning and
produce a less-polished finish
compared to glass beads. Aluminum
oxide and steel grit are suitable for use
breaks down quickly at pressures
greater than 40 PSI.
Walnut shells or plastic are sometimes
used for delicate parts, paint removal,
or when a polished finish is required.
Pressures from 20 to 100 PSI may be
used with these media, depending on
the application.
When changing from one type of media
to another, clean the cabinet interior
and media hoses thoroughly to avoid
cross contamination.
at pressures up to 100 PSI. Garnet
CAUTION
If your application requires aggressive media, such as aluminum oxide, garnet, or
steel grit, it is recommended that you use optional heavy duty ducting,
reclaimer lining, and 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.
If these options are not included with your system, they can be added. Optional
Rubber curtains for interior cabinet surfaces are also available. Consult your
Empire distributor for details.
Empire Abrasive Equipment Company
3.2 Media Loading
Cabinets With Reclaimers:
Step 1: With the cabinet switch OFF,
load media through the reclaimer
Glass Beads Aluminum Oxide Steel Shot or Grit
Suction 10 lb. 15 lb. 25 lb. 5 lb.
Pressure 75 lb. 100 lb. 200 lb. 30 lb.
Cabinets Without Reclaimers:
Step 1: With the cabinet switch ON,
load media through the cabinet door.
Glass Beads Aluminum Oxide Steel Shot or Grit
Suction 75 lb. 100 lb. 200 lb. 30 lb.
IMPORTANT
Be careful not to overfill pressure systems. Overfilling will cause malfunction
and premature wear. See Subsection 4.1 Daily Maintenance.
access door. Total capacity for each
media and system is shown below:
Walnut Shells or
Plastic
Total capacity for each media is shown
below:
Walnut Shells or
Plastic
3.3 Pneumatic Controls
The Pro-Finish
pneumatic control circuit to protect
workers, workers environment, and
activate the blast.
Step 1: Turning the system ON/OFF
Switch to ON, energizes the interlock
Solenoid valve, permits air to enter the
control air line to the foot treadle,
illuminates cabinet lights and start the
fan motor.
Step 2: The operator steps on the foot
treadle opening a three way control air
valve. Air enters the door interlock
supply tubing continuing to the door
air jets. If the part load/unload doors
are closed, latched, and door air jets
are sealed, the control air lines
pressurize and open the main blast air
valve (and the pressure systems
exhaust valve to close). The opening of
the main air valve starts the blast.
®
system uses a patented
Step 3: When the operator removes his
foot from the foot treadle, the three way
air valve close, shutting off air to the
controls, and exhausting all down
stream air. The control air line
pressure bleeds from the door interlock
supply tubing, main blast air valve (and
the pressure system exhaust valve).
This permits the main blast air valve to
close (and the pressure system exhaust
valve to open) stopping the blast.
Step 4: When a part load/unload door
is opened, the pad covering the door
interlock air jet is unseated. When the
foot treadle is pressed with a door open,
control air bleeds from the door air jet
opening, preventing the control circuit
from pressurizing. The main blast air
valve will not open, and blasting will
not occur.
Page 15
Empire Abrasive Equipment Company
The following schematic diagrams illustrate the pneumatic control circuits for suction
systems (Figure 12A) and pressure systems (Figures 12B). For each system type, the
cabinets are shown in blasting and non-blasting modes (shaded pipe is pressurized).
Figure 12A.
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Empire Abrasive Equipment Company
Figure 12B.
Page 17
Empire Abrasive Equipment Company
3.4 Equipment Start-up
Step 1: After checking that all pipe and
hose connections are tightly fastened,
turn on the plant compressed air and
open the (user furnished) manual (ball)
valve(s) controlling air flow to the
system.
Step 2: Turn the cabinet power switch
ON.
Step 3: Place parts to be blast-treated
in the cabinet. The parts must be free
of oil, grease, and moisture.
Suction Blast Pressure Blast
Glass Beads 30-60 PSI 20-60 PSI
Aluminum Oxide 30-100 PSI 20-80 PSI
Steel shot or grit 80-100 PSI 20-80 PSI
Walnut shells or plastic 20-100 PSI 20-80 PSI
Step 7: Hold the gun or nozzle at a
distance that produces the fastest
action. This distance may vary from 3
to 18 inches, depending on the work
piece and the desired finish. Avoid
pumping the foot treadle, as this will
decrease your efficiency and cause
premature wear of components.
Step 4: Close the cabinet door(s).
Step 5: Set the blast air pressure
regulator at the desired pressure.
Recommended operating pressure
ranges for various media are listed in
the table below. Do not exceed 125 PSI
blast pressure.
Step 6: Grip the suction gun or
pressure nozzle assembly firmly and
step on the foot treadle. After a few
seconds the abrasive flow will stabilize
and you will be ready for blasting.
The size of the effective blasting pattern
varies with the type and length of the
nozzle, air pressure, and the nature of
the work piece. Use the following chart
and diagram as a guide, but be aware
that the approximate pattern diameters
can only be determined by considering
each case individually.
Page 18
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