CAVIDYNE CaviBlaster 2828-E60 Manual
CAVIDYNETM, LLC
5077 Fruitville Rd., Suite
109-157 Sarasota, FL 34232
Phone: (352) 275-5319
Operation &
Maintenance
Manual
Model 2828-E60
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®model 2828-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.
Page 3/34
TABLE OF CONTENTS
1.0 UNIT SPECIFICATIONS............................................................................................... 5
2.0 GENERAL DESCRIPTION ........................................................................................... 6
2.1 Using this manual.......................................................................................................8
2.2 Conventions................................................................................................................9
2.3 Scope .........................................................................................................................9
2.4 Terms and Abbreviations............................................................................................9
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
4.2 Installation Location..................................................................................................14
4.3 Initial Set-Up.............................................................................................................15
4.3.1 Connecting the Water Source............................................................................... 15
5.0 OPERATION............................................................................................................... 19
5.1 Preparing the CaviBlaster®for Operation.................................................................19
5.2 Startup of the CaviBlaster®.......................................................................................19
5.3 Normal Operation .....................................................................................................21
5.4 Adjusting the CaviBlaster®for Maximum Performance.............................................21
5.5 Recommendations for Effective Results...................................................................23
5.6 Shutting Down the CaviBlaster.................................................................................23
6.0 MAINTENANCE.......................................................................................................... 27
6.1 Basic Preventive Maintenance Recommendations...................................................28
6.2 Pump Service ...........................................................................................................28
6.3 Inspection/Cleaning of Water Inlet Strainer ..............................................................29
6.6 Inspection / Maintenance of the Zero-Thrust Gun.....................................................30
7.0 WINTERIZATION........................................................................................................ 31
8.0 TROUBLESHOOTING................................................................................................ 32
9.0 REPLACEMENT PARTS............................................................................................ 34
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LIST OF FIGURES & TABLES
Figure 1.1 –CaviBlaster®2828-E60 Specifications........................................................5
Figure 2.1 –CaviBlaster®2828-E60 General Features...................................................7
Figure 2.2 –CaviBlaster®2828-E60 Control Panel.........................................................8
Figure 4.1 –Lifting Guidelines....................................................................................... 13
Figure 4.2 –Installation Guidelines............................................................................... 14
Figure 4.3 –Gravity Feeding Source............................................................................. 17
Figure 5.1 –Emergency Shut-Down ............................................................................. 20
Figure 5.2 –Gun Pressure Calibration.......................................................................... 20
Figure 5.3 –Gun Position for Best Results ...................................................................20
Figure 6.1 –Inspection / Cleaning Water Filter.............................................................29
Figure 6.2 _ Inspection / Maintenance Zero Thrust Gun…………………………..…..….30
This space intentionally left blank
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1.0 UNIT SPECIFICATIONS
The CaviBlaster®2828-E60 power unit consists of a 50HP (37 kW) electric motor and a
VX 100/200 triplex plunger pump. Detailed performance and specifications are listed
below:
Figure 1.1 –CaviBlaster®2828-E60 Specifications
(EOS)
CaviBlaster®2828-E60 Specifications
Nominal Pump Flow
28 GPM (106 LPM)
Nozzle Operating Pressure
2,800 PSI (190 BAR)
Motor
50 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
11 LBS (5 KG)
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2.0 GENERAL DESCRIPTION
The CaviBlaster®2828-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®2828-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 2,800 psi (190BAR) with safety overload protection rating to 3,080 psi
(209BAR).
For more information on the CaviBlaster®system please visit us at:
www.caviblaster.com
Lifting eyes
Forklift slots
High Pressure
Pump
Water
Connection
Panel
Figure 2.1 –CaviBlaster®2828-E60 General Features
Unloader valve
Pressure PumpElectric Engine
Base Plate
Control Box
Feed/suction
hose. 1-1/4”
cam-lock
Figure 2.2 –Caviblaster® 2828-E60 Control panel
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/study the section, and seek
assistance from CaviDyneTM or other personnel familiar with the operation of this
equipment.
Pressure hose
3/4” JIC
By-Pass hose
1” cam-lock
Emergency stop
HPP Motor
on/off switch
Feed pump
on/off switch
Main power
switch
Feed pump
indicator
light
HPP
Motor run
indicator
light
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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 sectionname 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-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.
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
(EOS)
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3.0 SAFETY INFORMATION
The CaviBlaster®2828-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 2828-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®2828-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.
CaviDyneTM, 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.
Ensure that there is a safe area to work while operating
the CaviBlaster®2828-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.
CaviDyneTM 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 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.
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)
Page 13/34
For more information please email sales@cavidyne.com or call 1-(352)275-5319
4.0 INSTALLATION
The CaviBlaster®2828-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 CaviDyneTM 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
Lift Unit from
Underneath
Frame
Lift unit using
lifting eyes
Page 14/34
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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.
Figure 4.2 –Installation Guidelines
Allow access to
control panel
Allow access
for general
service
Allow access
for general
service and
water
connection
panel
Grounding lug locations
Page 15/34
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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).
4.3.1 Connecting the Water Source
The CaviBlaster®power unit can be used with seawater orfresh water. Note theunit 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
Pump oil may have been removed for shipment. Check
oil level prior to starting.
Page 16/34
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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 connectionunless 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.
4.3.3 Three water supply conditions are acceptable for the CaviBlaster®
power unit.
a) Forced inlet water condition using the supplied electric water pump.
b) An outside water source capable of supplying a minimum of 40GPM (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.
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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.
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 CaviBlaster®with 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.
Water level
Pump inlet must be
below the tank outlet
Page 18/34
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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(115LPM). A minimum flowof 40 GPM (150LPM) isrecommended 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).
(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.
Page 19/34
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5.0 OPERATION
The CaviBlaster®2828-E60 should be operated by two (2) properly trained individuals.
One, the diver, operates the zero-thrust gun, while the other operates the power unit. Both
operators should be in audio or visual communication with each other.
The CaviBlaster®2828-E60 should only be operated by
properly trained personnel who are familiar with the
contents of the manual. Review the safety
requirements found in Section 3.0 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 also be completed after each use.
1) Inspect the CaviBlaster®power unit, electric power cord, hoses, JIC fittings
and gun for any signs of damage.
2) Check that the motor is clean and ventilation openings are clear.
3) Inspect the inline strainer and filter media, to ensure that neither are clogged
(See Figure 6.1). Clean or replace as necessary.
4) Check for proper pressure pump oil level (See pump Owner’s Manual found
in the Appendix). Add oil (SAE 30 non-detergent) if necessary.
5.2 Startup of the CaviBlaster®
Before starting the CaviBlaster®2828-E60 power 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.
1) Verify that the unit has been properly prepared for operation as described
in Section 4.
Page 20/34
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2) Unroll sufficient length of hose to reach the operating location and connect
the gun to the high-pressure hose
3) Turn the E-Stop button and pull out to release (See Figure 5.1).
4) Turn the main power switch ON.
5) Turn the feed pump switch, SW2, ON and wait for the indicator light to turn
on.
6) Turn the HPP motor switch, SW1, ON and wait for the indicator light to turn
on. Note that the motor is equipped with a “soft start” starter and takes 3-4
seconds for the motor to start after being turned ON.
7) When the diver is ready to commence cleaning operations, ensure that the
system is properly and fullyprimed and the diver gun is submerged in water.
If the diver is not wearing a helmet, hearing protection is recommended.
CaviDyneTM suggests vented earplugs such as “Doc’s Proplugs” for diver
hearing protection.
8) Wear neoprene or rubber gloves to protect the hands and follow all safety
regulations that may be applicable to the work being performed.
9) Pull the gun trigger to the open or ON position. (See figure 5.3)
10) The system is now ready to operate.
Figure 5.1 –Emergency Shut Down Switch On
DO NOT START THE MOTOR UNTIL THE DIVER IS
READY FOR UNDERWATER OPERATION.
Push on the red knob to
shut-down motor, twist and
pull the red knob out to
release motor shut-down.
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