CAVIDYNE CaviBlaster 2828-D Installation guide

CAVIDYNETM, LLC
5077 Fruitville Rd., Suite
109-157 Sarasota, FL 34232
Phone: [phone]
Operation &
Maintenance
Manual
Model 2828-D

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CaviDyne,TM LLC is not responsible for damages or
injuries resulting from a failure to comply with instructions
in this manual. Please read entire manual carefully before
use.
The CaviBlaster®2828 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.

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TABLE OF CONTENTS
1.0 UNIT SPECIFICATIONS................................................................................................5
2.0 GENERAL DESCRIPTION ............................................................................................6
2.1 Using this Manual (Version 1.3)........................................................................... 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 Battery Terminals................................................................. 17
4.3.2 Connecting the Water Source....................................................................... 18
5.0 OPERATION................................................................................................................22
5.1 Preparing the CaviBlaster®for Operation............................................................22
5.2 Startup of the CaviBlaster®.................................................................................. 23
5.3 Normal Operation ................................................................................................ 24
5.4. Adjusting the CaviBlaster®for maximum performance.......................................26
5.5. Recommendations for Effective Results............................................................. 29
6.0 MAINTENANCE...........................................................................................................32
6.1 Basic Preventive Maintenance Recommendations..............................................33
6.2 Diesel Engine Service..........................................................................................34
6.3 Pump Service ......................................................................................................34
6.4 Inspection/Cleaning of Water Inlet Strainer and Filter.......................................... 34
6.5 Inspection / Maintenance of the belt drive system...............................................36
6.6 Inspection / Maintenance of the Zero-Thrust Gun................................................ 38
8.0 TROUBLESHOOTING.................................................................................................40
9.0 REPLACEMENT PARTS.............................................................................................42
APPENDIX - COMPONENT LITERATURE.......................................................................43

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LIST OF FIGURES & TABLES
Figure 1.1 –CaviBlaster®2828 Specifications................................................................5
Figure 2.1 –CaviBlaster®2828 Cleaning Options...........................................................7
Figure 2.2 –CaviBlaster®2828 General Features ..........................................................8
Figure 2.3 –CaviBlaster®2828 Control Panel ................................................................9
Figure 4.1 –Lifting Guidelines.......................................................................................15
Figure 4.2 –Installation Guidelines...............................................................................16
Figure 4.3 –Reconnecting the Battery Terminals.........................................................18
Figure 4.4 –Gravity Feeding Source.............................................................................19
Figure 5.1 –Engine Emergency Shut-Down and Throttle Control.................................26
Figure 5.2 –Gun Pressure Calibration..........................................................................28
Figure 5.3 –Gun Position for Best Results ...................................................................30
Figure 6.1 –Inspection / Cleaning Water Strainer/Filter................................................35
Figure 6.2 –Inspection / Belt tension............................................................................36
Figure 6.3 –Inspection / Belt tension............................................................................37
Figure 6.3 –Zero-Thrust Gun........................................................................................38
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1.0 UNIT SPECIFICATIONS
The CaviBlaster®2828 power unit consists of a 51HP (38 kW) Kubota V2403-Turbo
diesel power-pack and a UDOR VX-100/200 positive displacement triplex plunger
pump. Detailed performance and specifications are listed below:
CaviBlaster®2828 Specifications
Nominal Pump Flow
28 GPM (106 LPM)
Operating Pressure
2800 PSI (193 BAR)
Engine
51 HP (38kW) Diesel Powered (Kubota V2403-Turbo)
Installation Environment
Outdoor enclosed or exposed
See Section 4 for installation requirements
Fuel Requirements
Diesel fuel (ASTM Grade No. 1-D or 2-D)
Fuel Tank Capacity
50 Gallons (190 Liters)
Water Inlet Pressure Limits
0-PSI (Atmospheric Pressure) to 70-PSI Maximum
(0 BAR to 4.8 BAR) See Section 4 for further requirements
Overall Unit Dimensions (L x W x H)
51” x 51” x 63” (130 cm x 130 cm x 155 cm)
Maximum Pressure Hose Length
600 LF (200 meters) of 3/4” diameter
Power Unit Weight (Dry)
1600 LBS (726 KG)
Figure 1.1 –CaviBlaster®2828 Specifications
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2.0 GENERAL DESCRIPTION
The CaviBlaster®2828 high-pressure water power unit allows the operator to use the
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 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 diesel-powered high-pressure pumping unit with connecting
high pressure hose which is capable of operating one 2828 Zero-Thrust Dump Gun (28
gpm, 106 LPM, flow); two 1428 Zero-Thrust Guns (14 gpm, 53 LPM, flow per gun); or
one DoubleDome (28 gpm, 106 LPM, flow total) with four rotating nozzles. It is
important to use only the guns/dome specified in order to maintain flow rates, pressure
and cleaning capability. When operating with the 2828 Zero-Thrust Dump Gun, closing
the trigger valve causes water to dump through the dump valve in the handle of the gun.
When operating with two 1428 Zero-Thrust guns, closing the trigger valve of one gun
allow the other gun to function normally while the flow for the closed gun goes to bypass
at the unit. Closing both trigger valves causes the power unit to go into full bypass
mode, unloading the engine and the pump. The DoubleDome is also equipped with a
trigger gun when used by a diver, closing the trigger valve causes the power unit to go
into bypass mode, unloading the engine and the pump. DoubleDomes used on ROVs
do not have a trigger valve and water flow is controlled by the CaviBlaster® unit.
FULL LOAD is defined as the engine at full throttle / full
speed. If partially throttled, the engine will stall, creating
an undesirable running condition for the belt drive system.
The CaviBlaster®2828 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 booster pump supplied with the power unit; or from a gravity storage feed tank.
The unit is equipped with many features to maintain operator safety while operating at
pressures of 2,800-psi (193 BAR).

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2828 Zero-Thrust Dump Gun
Flow Capacity 28 GPM (106 LPM)
1428 Zero-Thrust Gun
Flow Capacity 14 GPM (53 LPM) Per Gun
DoubleDome
Flow Rate 28 GPM (106 LPM)
Figure 2.1 –CaviBlaster®2828 Cleaning Options

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Pressure pump
Suction filter
Lifting eyes
Forklift slots
Control panel
See Fig 2.2
Figure 2.2 –CaviBlaster®2828 General Features
For more information on the CaviBlaster®system please visit us at:
www.caviblaster.com

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Figure 2.3 –CaviBlaster®2828 Control Panel
Feed pump switch
(pull on/push off)
Feed pump electrical
connection
Engine ignition
Throttle cable control
(Push red button to release/
Twist black knob to lock)
Pressure hose –3/4” JIC
By-pass hose (Dump)
1“ cam-lock
Feed or suction hose
1-1/2” cam-lock

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2.1 Using this Manual (Version 1.3)
Every attempt has been made to ensure that this documentation is complete and
accurate at the time of publication. It is imperative; however, that anyone
attempting to use this manual must have good comprehension of how this
equipment operates. Further, this manual can in no way replace the common
sense of an individual. If at any time this manual seems to contradict itself, or
common sense, discontinue the procedure, re-read the section, and seek
assistance from CaviDyneTM or other personnel familiar with the operation of this
equipment.
2.2 Conventions
The first time a component is mentioned, it is typically followed by a figure
reference; e.g., Ignition key (See Figure 2.2.) 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®
2828. It is essential that personnel who will operate and/or service this equipment
familiarize themselves with this manual. Standard components, such as the unit
engine and pump, are covered by the manufacturer’s literature found in the
Appendix.
NOTE FOR ELECTRONIC COPY OF THIS MANUAL
The electronic version of this manual contains many additional resources
such as component data sheets and service manuals. To best utilize these
resources, it is recommended to view with Adobe Reader version 7.0 or
higher. Go to www.adobe.com for this free software download.