Caviblaster 3040-E Manual

CAVIDYNE LLC
5077 Fruitville Rd., Suite
109-157 Sarasota, FL 34232
Phone: [phone]
Operation &
Maintenance
Manual
Model 3040-E

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CAVIDYNE LLC is not responsible for damages or injuries
resulting from a failure to comply with instructions in this
manual. Please read and study the entire manual carefully
before use.
The CaviBlaster model 3040-E60 must only be operated
and maintained by trained personnel.
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 adequate voltage and amperage under load.
CAUTION: DO NOT USE THIS EQUIPMENT TO CLEAN
SENSITIVE SURFACES as LED-Lights, Underwater Lights,
Electronic Equipment, etc.

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Table of Contents
1.0 UNIT SPECIFICATIONS...............................................................................................5
2.0 GENERAL DESCRIPTION...........................................................................................6
2.1 Using this manual....................................................................................................10
2.2 Conventions.............................................................................................................10
2.3 Scope.......................................................................................................................10
2.4 Terms and Abbreviations ........................................................................................11
3.0 SAFETY INFORMATION............................................................................................12
3.1 Personal Safety .......................................................................................................12
3.2 Personal Protective Equipment...............................................................................13
3.3 Modification to the Equipment.................................................................................14
4.0 INSTALLATION..........................................................................................................15
4.1 Uncrating and Lifting................................................................................................15
4.2 Installation Location.................................................................................................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 Basic Preventive Maintenance Recommendations................................................30
6.2 Pump Service...........................................................................................................30
6.3 Inspection/Cleaning of Water Inlet Strainer............................................................31
6.4 Inspection / Maintenance of the Zero-Thrust Gun..................................................32
7.0 WINTERIZATION........................................................................................................33
8.0 TROUBLESHOOTING................................................................................................34
9.0 REPLACEMENT PARTS............................................................................................36

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Table of Figures
Figure 1.1 –CaviBlaster 3040-E60 Specifications …………………...…...……5
Figure 2.1 –CaviBlaster 3040-E60 General Features ………………...…….…7
Figure 2.2 –CaviBlaster3040-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

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1.0 UNIT SPECIFICATIONS
The CaviBlaster 3040-E60 power unit consists of a 100HP (74.5 kW) electric motor and
a HPP GLR 109/290 triplex plunger pump. Detailed performance and specifications are
listed below:
CaviBlaster 3040-E60 Specifications
Nominal Pump Flow
29 GPM (110 LPM)
Nozzle 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 Length
600 LF (200 meters) of 3/4” diameter
Power Unit Weight (Dry)
2,550 LBS (1160 KG)
Zero-Thrust Gun Weight
4.4 LBS (2 KG)
Figure 1.1–CaviBlaster 3040-E60 Specifications
(EOS)

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2.0 GENERAL DESCRIPTION
The CaviBlaster 3040-E60 high-pressure water power unit is designed to use water flow
and pressure to generate cavitation at the end of the proprietary nozzle.
The CaviBlaster cleans the surface of any underwater structure using the energy
released by the implosion of the bubbles created during the cavitation process. When
directed at the surface being cleaned, the energy released by the collapsing bubbles
causes marine growth to be removed from the surface.
The system consists of a portable, zero-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 allows quick deployment and/or installation of the unit. Water
can be supplied from either a pressurized source, directly from the natural source via an
electric feed pump supplied with the power unit, or from a gravity feed storage tank.
The unit is equipped with many features to maintain operator safety while operating at
pressures of 4,000 psi (276 BAR) with safety overload protection rating to 5,000 psi
(344 BAR).

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Figure 2.1 –CaviBlaster 3040-E60 General Features

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Figure 2.2 –CaviBlaster 3040-E60 Control panel

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2.1 Using this manual
While every effort has been made to ensure the accuracy and completeness of
the content of this documentation, CaviDyne, LLC, its employees or associated
organizations shall have neither liability nor responsibility to any person or entity
with respect to any loss or damage arising from its use. Always take appropriate
and adequate precautions to prevent damage or injury. Should you, at any time,
have questions or concerns, please, contact our headquarters, as we will be
happy to assist you. While quality and your satisfaction are our goal, nothing
takes precedence over your safety.
2.2 Conventions
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 space intentionally left
blank” will appear where there is more than 3 inches of white space.
(EOS) will appear above the page number on the last page of each section.
2.3 Scope
This manual covers installation, operation, and maintenance of the CaviBlaster
3040-E60. It is essential that personnel who will operate and/or service this
equipment familiarize themselves with this manual. Standard components, such
as the unit motor and pump, are covered by the manufacturer’s literature found in
the Appendix.

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2.4 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

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3.0 SAFETY INFORMATION
The CaviBlaster 3040-E60 power unit is an inherently powerful and potentially
dangerous piece of equipment; however, with proper care and training it can be
operated safely. The 3040-E60 must only be operated by personnel that have read and
understand this manual. It is intended to reinforce and review safety techniques to
prevent personal injuries and property damage.
Users must comply with all local, state, and national laws concerning high-pressure
water jetting equipment as well as all underwater work regulations.
It is strongly recommended that this entire manual be reviewed in-depth before
operating or servicing this equipment. Service work 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. Appropriate protective equipment should always be worn. Operation of the
system without the proper equipment and training can result in personal injury.
CAVIDYNE LLC is not responsible for damages resulting
from a failure to comply with instructions in this manual.
Please read carefully before use.
If maintenance or repair of the CaviBlaster gun is being conducted
out of the water, remember that the zero-thrust gun has front and
rear jets. Never direct the jet streams at a person or animal. Never
direct the jet streams toward power lines or other high voltage
equipment.

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Ensure that there is a safe area to work while operating
the CaviBlaster 3040-E60.
Seek immediate medical attention if the operator suffers an
injury as the result of contact with the high-pressure water
stream. Serious personal injury can result from an
untreated water injection wound.
3.2 Personal Protective Equipment
Always wear appropriate Personal Protective Equipment (PPE) when operating
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 by bursting cavitation
bubbles and prevent the cavitation bubbles from contacting the operators’ hands.
The gloves will also protect operators’ hands from the initial shockwave when the
zero-thrust gun is activated.
Failure to wear appropriate PPE may result in personal
injury.

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3.3 Modification to the Equipment
Do not make any unauthorized modifications or repairs to this equipment.
Components used throughout this assembly were specifically designed or
selected to safely meet the unique high-pressure requirements. Only replace
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 nozzles other than those
supplied or specified by the manufacturer may lead to
catastrophic equipment failure and serious personal
injury.
(EOS)

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4.0 INSTALLATION
The CaviBlaster 3040-E60 must be installed in accordance with the requirements
outlined below. The unit can be installed in a vehicle to allow for maximum mobility and
flexibility.
4.1 Uncrating and Lifting
Unpack the equipment and inspect for damage. If damage is found, 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 frame. Verify
that lifting equipment is rated for the weight listed in Section 1.0 UNIT
SPECIFICATIONS and that the unit is stable before lifting.
Figure 4.1 –Lifting Guidelines

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4.2 Installation Location
For maximum flexibility the CaviBlaster power unit should be installed in an area
where it is capable of reaching both its electric and water source and anticipated
cleaning targets within acceptable power cable and hose lengths. The
CaviBlaster power unit can be installed in an enclosed* or open environment.
* Enclosed installations 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 above to
conduct service and repair work. Take note of frequently serviced areas such as
the in-line strainers and motor couplings.
✓Allow Access For General Service
✓Allow Access To The Hose Connections Panel
✓Allow Access To Electric Panel

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Figure 4.2 –Installation Guidelines
4.3 Initial Set-Up
After first receiving the CaviBlaster power unit, the following must be checked
and completed:
1) Check / Add pump oil (See Pump Manual located in the APPENDIX).
2) Push in the Emergency Motor Shutoff (E-Stop) button.
3) Turn the main power 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 and lock the control panel door.
9) Connect the feed or suction hose (See Section 4.3.2).
10) Connect the bypass hose (See Figure 2.2).
11) Connect the pressure hose (See Figure 2.2).

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4.3.1 Connecting the Water Source
The CaviBlaster power unit can be used with seawater or fresh water. Note the unit
must be flushed with fresh water for 1-2 minutes after each use in seawater to ensure
long service life.
An electric boost pump is installed to provide positive inlet water pressure to the main
pressure pump. The power unit incorporates a high-flow centrifugal feed pump to
support the main pump system. The feed pump is capable of providing 50 to 70 GPM of
water for the system.
4.3.2 Priming the System Using the Feed Pump System
Attention to priming the system is necessary. The feed water suction hose inlet
connection is located on the water connection panel (See Figure 2.2). The (clear)
suction hose should be 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 hose to cause an air lock leading to the
feed pump.
The feed pump system is fully capable of self-priming. The feed pump should be
charged with water to more effectively draw from the source. It is suggested a positive
pressure water source be utilized to initially charge the feed pump system.
Note: The feed pump may require upwards of 5 to 7 minutes to draw sufficient water to
prime the system before starting the main pump system.
Once fully primed should a restart be needed, confirm priming is complete, without
trapped air pockets.
Pump oil may have been removed for shipment. Check
oil level prior to starting.

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4.3.3 Water Supply Conditions.
a) Forced inlet water condition using the supplied electric water pump.
b) An outside water source capable of supplying a minimum of 40 GPM (150
LPM) at a maximum pressure of 50-PSI (3.5 BAR).
c) Gravity feeding water source (See Figure 4.3). Use a hose with a diameter of
at least 1-1/2” to connect the water tank 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 Figure 2.2). Place the other end of
the hose in the water supply.
•THE PUMP SYSTEM MUST BE FULLY PRIMED BEFORE STARTING THE
HPP PUMP OR SERIOUS DAMAGE TO HPP PUMP WILL OCCUR. REFER
TO SECTION 4.3.2 (ABOVE) FOR PRIMING INSTRUCTIONS.

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b) Using Force Feed Supply from an alternate source:
•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).
•When feeding the CaviBlasterwith an alternate water source, the source must
be capable to supply water at a volume of greater than 28 gallons per minute
(106 LPM) at a maximum pressure of 50-psi.
•Connect a 1-1/2” cam-lock socket on the water supply hose to the water inlet
connection on the control panel (See Figure 2.2). Confirm system is primed.
c) To Use Gravity Feed:
•Locate the water supply tank so that the outlet of the supply tank is higher
than the water inlet on the control panel (See Figures 2.2 and 4.3).
•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 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 SERIOUS DAMAGE TO HPP PUMP WILL OCCUR. REFER
TO SECTION 4.3.2 ABOVE FOR PRIMING INSTRUCTIONS.
•It is essential that adequate water is supplied to the water supply tank to
maintain the water level several inches above the tank outlet. Failure to
maintain an adequate water level in the supply tank during operation could
starve the pressure pump of water causing damage to the seals or other
components of the pressure pump.
Ensure that the water source can reliably deliver the maximum pump flow of 30
GPM (115 LPM). A minimum flow of 40 GPM (150 LPM) is recommended to
ensure that the pump is not starved of water. If connecting to a gravity feed tank,
locate the tank outlet above the water inlet connection on the power unit to
ensure a flooded suction line. (See Figure 4.3).

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(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.