CAVIDYNE CAVIBLASTER 2040-ROV Manual

CAVIDYNETM, LLC
5077 Fruitville Rd.; Ste 109-157
Sarasota, FL 34232
Phone: (352) 275-5319
www.caviblaster.com
Model 2040-ROV
Version 1.0

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 2/26
CAVIDYNETM 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®2040-ROV 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.

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 3/26
TABLE OF CONTENTS
1.0 UNIT SPECIFICATIONS................................................................................................5
2.0 GENERAL DESCRIPTION ............................................................................................6
2.1 Using this Manual.......................................................................................................8
2.2 Conventions................................................................................................................8
2.3 Scope .........................................................................................................................8
2.4 Terms and Abbreviations............................................................................................8
3.0 SAFETY INFORMATION.............................................................................................10
3.1 Personal Safety ........................................................................................................10
3.2 Personal Protective Equipment.................................................................................11
3.3 Modification to the Equipment...................................................................................12
4. 0 INSTALLATION..........................................................................................................13
4.1 Uncrating and Lifting.................................................................................................13
4.3 Initial Set-Up.............................................................................................................14
5.0 OPERATION................................................................................................................15
5.1 Preparing the CaviBlaster®for Operation.................................................................15
5.2 Startup of the CaviBlaster®......................................................................................15
5.3 Normal Operation .....................................................................................................16
5.4 Adjusting the CaviBlaster®for Maximum Performance ............................................17
5.5 Recommendations for Effective Results...................................................................19
6.0 MAINTENANCE...........................................................................................................22
6.1 Basic Preventive Maintenance Recommendations...................................................23
6.3 Pump Service ...........................................................................................................23
6.4 Inspection/Cleaning of Water Inlet Strainer ..............................................................23
8.0 TROUBLESHOOTING.................................................................................................24
9.0 REPLACEMENT PARTS.............................................................................................25
APPENDIX - COMPONENT LITERATURE.......................................................................26

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 4/26
LIST OF FIGURES & TABLES
Figure 1.1 –CaviBlaster® 2040-ROV Specifications……………………………………..….5
Figure 2.1 –CaviBlaster®2040-ROV General Features.................................................7
Figure 4.1 –Lifting Guidelines.......................................................................................13
Figure 5.2 –Lance Position for Best Cleaning results……………………………..………19
This space intentionally left blank

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 5/26
1.0 UNIT SPECIFICATIONS
The CaviBlaster®2040-ROV power unit consists of a 55HP (37 kW) Cross hydraulic
gear motor power-pack and a CAT 3560 triplex plunger pump. Detailed performance
and specifications are listed below:
CaviBlaster®2040-ROV Specifications
Nominal Pump Flow
20 GPM (76 LPM)
Nozzle Operating Pressure
4,000-PSI (275 BAR)
Driver
50M052 Cross Hydraulic Gear Motor
Installation Environment
Submersible
Hydraulic Oil Flow Requirements
*See below.
Overall Unit Dimensions (L x W x H)
30” x 28” x 13”(76 cm x 71 cm x 33 cm)
Maximum Pressure Hose Length
300 LF (100 meters) of 3/4” (1.9 cm) diameter
Power Unit Weight (Dry)
273 LBS (124 KG)
*Hydraulic Power Unit must be capable of operating the water pressure pump at 1160 rpm and 55 HP.
Consult CaviDyneTM regarding the suitability of your existing Hydraulic Power Unit.
Figure 1.1 –CaviBlaster®2040-ROV Specifications
This space intentionally left blank
(EOS)

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 6/26
2.0 GENERAL DESCRIPTION
The CaviBlaster®2040-ROV 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 portable high-pressure pumping unit designed for submersible
ROV use and a high pressure cavitation lance (connected to ROV manipulator) with
connecting high pressure hose.
The CaviBlaster®2040-ROV power unit is a complete “plug and play” system built on a
supporting platform that allows quick deployment and/or installation of the unit. Water is
supplied directly from the unit operating environment.
The unit is equipped with many features to maintain safety while operating at pressures
of 4,000-psi (275 bar).
For more information on the CaviBlaster®system please visit us at:
www.caviblaster.com

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 7/26
Figure 2.1 –CaviBlaster®2040-ROV General Features
Oil pressure
compensator
(pump side
must be
completely
filled with oil)
Pressure pump
(pump must be
completely filled
with oil)
Secondary relief
valve
Hydraulic motor
Pulsation
dampener
Pressure
regulating valve
Water inlet
strainers
Hydraulic oil connections
(direction of pump rotation
not important)
High pressure water
hose connection
Oil pressure compensator
fill port cap

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 8/26
2.1 Using this Manual
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., 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®
2040-ROV. 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.
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

© 2013 O&M Manual Version 1.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 9/26
PSI
Pounds Per Square Inch (without suffix, assumed to be gauge pressure).
(EOS)

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 10/26
3.0 SAFETY INFORMATION
The CaviBlaster®2040-ROV power unit is an inherently powerful and potentially
dangerous piece of equipment; however, with proper care and training it can be
operated safely. The 2040-ROV 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.
Note that the oil pressure compensator is not a pressurized component and therefore
not a safety hazard. It is open at one end and connected to the pressure pump oil
chamber at the other end. Its purpose is simply to balance the oil pressure in the water
pressure pump with the unit’s surrounding environmental pressure to prevent damage
to the water pressure pump.
3.1 Personal Safety
Operation of the CaviBlaster®2040-ROV underwater submersible ROV-mounted
cleaning system must only be operated by personnel who have been trained in
its use. Operation of the system without the proper training can result in property
damage and damage to the CaviBlaster® unit.
CaviDyneTM, LLC is not responsible for damages resulting
from a failure to comply with instructions in this manual.
Please read carefully before use.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 11/26
If maintenance or repair of the CaviBlaster®is being
conducted out of the water, remember that the unit
generates a high pressure water jet stream. Never
direct the jet stream at a person or animal. Never direct
the jet stream toward power lines or other high voltage
equipment.
Ensure that there is a safe area to work while operating
or maintaining the CaviBlaster®2040-ROV.
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 performing maintenance or calibration on this equipment.
Personnel operating or working in the vicinity of the power unit should wear
appropriate hearing protection when operating the CaviBlaster®during
maintenance or calibration procedures.
Personnel performing maintenance or calibration procedures on the CaviBlaster®
2040-ROV 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 lance is activated.
Failure to wear appropriate PPE may result in personal
injury.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 12/26
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 CaviDyneTM. 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.
(EOS)

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 13/26
4. 0 INSTALLATION
The CaviBlaster®2040-ROV must be securely attached to the ROV using the vibration
mounts supplied or other secure fastening mechanism.
4.1 Uncrating and Lifting
Unpack the equipment and inspect for damage. If damage is found, immediately
contact CaviDyneTM and the shipping company. If the unit will not be installed
immediately, provide adequate indoor storage to protect against damage.
The CaviBlaster®power unit should be lifted from underneath. Do not use
components of the CaviBlaster® to lift the entire unit.
Figure 4.1 –Lifting Guidelines
Lift from underneath
only
Do NOT use hoses
or components to lift
Do NOT use hoses
or components to lift

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 14/26
4.3 Initial Set-Up
After first receiving the CaviBlaster®power unit, the following must be completed:
See Figures 2.1 for item locations.
1. Add oil to pump by completely filling pump to top of fill port.
2. Install fill plug.
3. Stand unit on end with pump motor at top.
4. Remove oil pressure compensator fill port cap.
5. Fill oil pressure compensator and hose with oil.
6. Allow unit to sit for several minutes to vent any trapped air.
7. Top-off oil as required.
8. Replace oil pressure compensator fill port cap.
9. Set unit back down on vibration mounts.
10.It is important that there is no air trapped in the pump oil system.
11.Connect hydraulic power unit hoses.
12.Connect water pressure hose.
The CaviBlaster®2040-ROV can be used with seawater
but must be flushed and rinsed with fresh water after
every use in seawater. Failure to flush and rinse the
power unit after use in seawater will result in increased
wear and tear on components and can cause the pump
valve(s) to stick in the open position. This will prevent the
system from producing the correct operating pressure.
EOS
Pump fluids may have been removed for shipment.
Check ALL fluid levels prior to starting.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 15/26
5.0 OPERATION
The CaviBlaster®2040-ROV should only be operated
by properly trained personnel who are familiar with
the contents of the manual. Review the safety
requirements found in Section 3 before operating.
5.1 Preparing the CaviBlaster®for Operation
The following checklist should be completed in advance, so that the unit is
always ready for immediate use. This should be completed after each use.
1) Inspect the CaviBlaster®power unit, hoses, JIC fittings and lance for any
signs of damage.
2) Inspect the water inlet strainer to ensure that it is not clogged (See Figure
2.1). Clean if necessary.
3) Check for proper pressure pump oil level (See pump Owner’s Manual found
in the Appendix). Add oil (SAE 30 non-detergent) if necessary. PUMP MUST
BE COMPLETELY FILLED.
Incorrect oils should not be used as they may
damage the equipment.
5.2 Startup of the CaviBlaster®
Before starting the CaviBlaster®2040-ROV unit, review all safety requirements
found in Section 3.0 SAFETY INFORMATION. This equipment should only be
operated by individuals who have read and understand the CaviBlaster®
Operation and Maintenance Manual.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 16/26
1) Verify that the unit has been properly prepared for operation as described
in Section 4.0 INSTALLATION.
2) Verify that the lance is properly connected to the CaviBlaster® and the
ROV.
3) Run the ROV hydraulic system to verify that the CaviBlaster® hydraulic
motor and pressure pump are functioning correctly.
5.3 Normal Operation
Normal operation of the CaviBlaster®system is defined as user control of water
flow via the lance. In the absence of a diver, control of the power unit is
accomplished by the ROV manipulator. Should a problem develop with the
control valve, discontinue using the CaviBlaster®until fixed.
Review the safety requirements for PPE and safe
operation before proceeding.
1) The ROV hydraulic system needs to be operating at a capacity that
matches the water pressure pump requirements for the CaviBlaster®
2040-ROV to function correctly. Unlike gasoline or diesel engines, a
hydraulic motor will run as fast as the oil supply it receives, which means
that the hydraulic oil supply must be adjusted to match the water pressure
pump requirements. Consult with CaviDyneTM to determine if your high
pressure oil supply unit is suitable for use with the CaviBlaster®2040-
ROV.
2) Activate the cleaning cavitation stream by turning ON the hydraulic power
unit.
Although the CaviBlaster®system is safe to use when
submerged in water, the system generates a high-pressure
(up to 4,000-psi [275 bar]) water stream, which can cause
injury when the lance is out of the water. ALWAYS keep the
lance submerged when the pressure pump is engaged.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 17/26
5.4 Adjusting the CaviBlaster®for Maximum Performance
The pressure at the nozzle of the lance has to be maintained within certain limits
to achieve cavitation and for best performance results. If using a calibration
pressure gauge situated between the pressure hose and the CaviBlaster®lance,
the water pressure should be 4,000-psi (275 bar) with the lance submerged and
the hydraulic power unit operating. For best results, repeat this calibration
procedure if cleaning performance degrades, or every 3 months at a maximum.
To calibrate the pressure at the lance, follow the procedure below:
- Stop the hydraulic power unit to discharge any residual pressure in the hose
lines.
- Disconnect the lance from the main hose line.
- Attach the calibration gauge between the main hose line and the lance and
tighten the JIC connections. (See Figure 5.1)
- Submerge the lance. Because of the danger of the operator coming in contact
the water stream from the cavitating nozzle, CaviDyneTM does NOT
recommend calibrating the lance out of the water. Use extra care to avoid the
water stream if doing so.
- Ensure that the cavitation nozzle is pointed away from the diver’s or
operator’s hands, arms and body.
- Start the hydraulic power unit.
- Hold the lance tight and observe the calibration gauge (See Figure 5.1).
- Turn the knob on top of the pressure regulating valve until pressure reads
4,000-psi (275 bar) on the calibration gauge. Turning the knob clockwise will
increase the pressure and turning it counter clockwise will decrease the
pressure.
A CALIBRATION GAUGE IS RECOMMENDED WITH EVERY
UNIT. CONNECT BETWEAN THE END OF THE HOSE AND
THE LANCE.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 18/26
This space intentionally left blank
DO NOT ADJUST THE PRESSURE AT THE LANCE TO MORE
THAN 4,000-PSI (275 BAR). HIGHER PRESSURE WILL NOT
IMPROVE PEFORMANCE AND COULD RESULT IN SERIOUS
DAMAGE TO THE PUMP.
HOSES ARE RATED FOR 4,000-PSI (275 BAR) PRESSURES
ABOVE 4,000-PSI (275 BAR) COULD RESULT IN HOSE
FAILURE.

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 19/26
Figure 5.1 –Lance Pressure Calibration
5.5 Recommendations for Effective Results
When the ROV operator is ready to commence cleaning operations, verify that
the lance is securely attached to the manipulator.
Once the hydraulic power unit is operational and the water jet stream is flowing
from the lance, the ROV operator has to find the most effective distance between
the lance nozzle and the surface being cleaned. (See Figure 5.2)
Calibration gauge
Pressure hose
Lance

© 2013 O&M Manual Version 2.0 CaviDyneTM 5077 Fruitville Rd.; Ste 109-157 Sarasota, FL 34234 U.S.A. Phone 352.275 5319
Page 20/26
1. Engage the ROV’s hydraulic power unit to activate the CaviBlaster® unit.
2. The most efficient operating technique is to hold the nozzle 2-5 inches (5-12
cm) away from the surface to be cleaned and at a 25 to 45 degree angle to
the surface being cleaned (See Figure 5.2). The ROV operator needs to
observe the shape of the cavitating jet cone. At greater depths, the higher
ambient pressure will cause the jet cone to be shorter. The widest zone of the
cone is the most efficient part of the cavitating jet. Placing the nozzle closer
than 2 inches (5 cm) from the surface being cleaned will not allow for efficient
cavitation performance and will degrade the cleaning capability of the
CaviBlaster®system.
3. Follow all safety regulations that may be applicable to the work being
performed.
Figure 5.2 –Lance Position for Best Cleaning Results
Table of contents
Other CAVIDYNE Portable Generator manuals
Popular Portable Generator manuals by other brands

Winco
Winco WL16000HE-03/A Installation & operator's manual

Nature's Generator
Nature's Generator Nature's Power Pod user manual

Rigid Industries
Rigid Industries RD903612 Operator's manual

Firman
Firman P06702 Operator's manual

MG
MG BSKA 9,5 EV SS curve operating manual

P.Lindberg
P.Lindberg 9042042 Original user manual

Viessmann
Viessmann Vitobloc 200 EM-20/39 operating instructions

Generac Power Systems
Generac Power Systems GP3250 specification

Technix
Technix SR10OKV-5KW Operator's manual

MULTIQUIP
MULTIQUIP GA-2.5H Operating and parts manual

Westerbeke
Westerbeke 26.0 KW-50Hz Operator's manual

Analog way
Analog way Secure Power Unit quick start guide