Comco DirectFlo DF1400 Series Operation manual

Operation and Service Instructions
DirectFlo™ DF1400
Issue Date: January 2009
This manual covers all variations of the DF1400 series
(DF1400-1, DF1400-2, ETC)
Comco Inc.
2151 N. Lincoln Street
Burbank, California 91504
USA
Phone: [phone]
FAX: [phone]
www.comcoinc.com
Book P/N PF1430
File: DF1400.doc

Comco Inc. ii Issue Date: January 2009
Table of Contents
The Comco Warranty ............................................................................................iv
Safety Precautions ................................................................................................v
Chapter 1: The DirectFlo DF1400 .............................................................1-1
This chapter introduces you to the basic unit, including its
description, principles of operation, and detail specifications.
Overview....................................................................................................1-2
Figure 1-1, DirectFlo DF1400.........................................................1-2
How The DirectFlo Works..........................................................................1-3
Figure 1-2, DirectFlo Pressurized...................................................1-3
Figure 1-3, Modulator Open............................................................1-4
Figure 1-4, Modulator Closed.........................................................1-5
Detail Specifications...................................................................................1-6
Chapter 2: Getting Started........................................................................2-1
This chapter tells you what you need to have and what you
need to do to set up the DirectFlo.
The Proper Work Area...............................................................................2-2
Figure 2-1, Micro-abrasive Blasting System Requirements ............2-3
Figure 2-2, DirectFlo Reference Sheet...........................................2-4
What You Received with the DirectFlo.......................................................2-5
Basic Components of the DirectFlo............................................................2-6
Figure 2-3, External Component Locations.....................................2-7
Setup and Test ..........................................................................................2-8
Figure 2-4, Tank Inspection............................................................2-9
Chapter 3: Using the DirectFlo.................................................................3-1
This chapter discusses the selection of key operating
parameters such as abrasives and nozzles; and tells you
how to operate the DirectFlo for maximum efficiency.
Essence of Micro-Abrasive Blasting...........................................................3-2
Table 3-1, Factors Affecting Abrasive Blasting...............................3-3
Abrasive Selection.....................................................................................3-4
Table 3-2, Abrasives and Their Applications...................................3-5
Tank Orifice and Nozzle Selection .............................................................3-6
Table 3-3, Orifice Selection Chart...................................................3-7
Figure 3-1, Changing the Tank Orifice............................................3-7
Figure 3-2, Changing the Nozzle....................................................3-8
Table 3-4, Nozzle Chart..................................................................3-9
General Operation of the DirectFlo ............................................................3-12
Figure 3-3, Filling the Abrasive Tank..............................................3-13
Figure 3-4, Controls and Indicators.................................................3-14

Comco Inc. iii Issue Date: January 2009
Table of Contents
Chapter 4: Maintenance............................................................................4-1
This chapter tells you what you need to do to keep the
DirectFlo operating properly.
Normal Maintenance..................................................................................4-2
Table 4-1, Maintenance Intervals ...................................................4-3
Parts Subject to Normal Wear....................................................................4-4
Figure 4-1, Moving the Hose in the Vent Pinch...............................4-4
General Maintenance.................................................................................4-7
Figure 4-2, Regular Maintenance Items..........................................4-8
Auxiliary Equipment...................................................................................4-9
Moisture.....................................................................................................4-10
Chapter 5: Trouble-shooting and Repair.................................................5-1
This chapter tells you what to do if you have a problem with
the DirectFlo.
Trouble-shooting........................................................................................5-2
Customer Service ......................................................................................5-2
How to Order Replacement Parts ..............................................................5-3
Common Problems, Causes, and Solutions...............................................5-4
Table 5-1, No Air Flow....................................................................5-4
Table 5-2, No Abrasive Flow ..........................................................5-5
Clogging ....................................................................................................5-6
Tank Cover................................................................................................5-7
Replacing the Abrasive Hose and Fittings..................................................5-8
Figure 5-1.......................................................................................5-9
Inspecting and Repairing the PowderGate.................................................5-13
Figure 5-2.......................................................................................5-13
Inspecting and Repairing the Modulator.....................................................5-15
Figure 5-3, Modulator Assembly.....................................................5-16
Air Pressure Regulator...............................................................................5-17
Chapter 6: Optional Equipment and Manual Supplements....................6-1
This chapter details optional equipment available on the DirectFlo,
and the use and servicing of these options.
Appendices
This appendix presents parts lists, drawings and schematics
for the DirectFlo DF1400.
Appendix A: Parts Lists ........................................................................................A-1
Major Assemblies and Principal Parts........................................................A-2
Standard Accessory Parts..........................................................................A-5
Recommended Spares..............................................................................A-6
Appendix B: Drawings and Schematics................................................................B-1

Comco Inc. iv Issue Date: January 2009
Welcome!
Welcome to the User’s Manual for the Comco DirectFlo™ model DF1400
Micro-abrasive Blaster! You have purchased the finest micro-abrasive blaster
available today, and this manual is designed to help you set up, operate, and
maintain the DirectFlo™ DF1400.
NOTE: Prior to setting up and operating your DirectFlo, the operator
and the department supervisor should carefully review this
entire manual.
The Comco Warranty
Comco warrants that the DirectFlo™ DF1400 will be free from all defects in material and
workmanship under normal use for a period of one year from the date of purchase or
2,000 hours of normal operation, whichever comes first.
The warranty period begins when the equipment ships from the Comco facility and
applies to the original owner only. Comco is not liable for damages from any cause or
use of such equipment beyond the cost of repairing any defective parts.
If the equipment fails to perform satisfactorily during the warranty period, Comco has the
option to do any one of the following: 1) Send replacement parts to the customer to be
installed by the customer; 2) Repair the unit at the customer’s facility; or 3) Request that
the unit be returned to the Comco factory. Comco shall furnish any replacement parts
without cost, F.O.B. the Comco factory in Burbank, California, provided that Comco is
notified of the defect within the warranty period. Any defective parts shall be returned to
Comco for inspection and analysis.
Exclusions
The above warranty does not apply to defects or problems resulting from improper or
inadequate maintenance by the customer; unauthorized modification or misuse; failure
to follow the operating instructions; the use of any supplies or parts, including but not
limited to nozzles, powders, and attachments, not manufactured or supplied by Comco.
The warranty also does not cover problems resulting from improper or inadequate
facilities (contaminated air, improper power) or items that should be expected to wear in
normal operation, such as nozzles, abrasives, tubing, or fittings.
This is Comco’s only warranty and is in lieu of all other warranties of
merchantability and fitness for any particular purpose. No representations or
warranties are authorized except as herein stated.

Comco Inc. v Issue Date: January 2009
Safety Precautions
General Safety Considerations
The DirectFlo has been designed to be safe to operate when used properly. Any
device that is pressurized and requires electrical power, however, requires that
certain safety precautions be observed to avoid potentially hazardous situations.
The primary safety-related issues involved in the use of the DirectFlo are listed
below and addressed in detail on the following pages.
1. Working with a device that is pressurized.
2. Working with an electrical device.
3. Working with a device that uses abrasive powders that could be
potentially dangerous if inhaled or ingested in large quantities or
put in constant contact with the skin.
4. General issues involved in operating machinery.
Working with a Device that is Pressurized
The DirectFlo uses pressurized air to perform its basic function. While Comco's
blasting machines incorporate relief valves and check valves to minimize the risk
of an accident related to air pressure, Comco also recommends the following:
√The air supply system should have a shutoff valve located
upstream of the blasting machine so that the supply pressure can
be turned off independently of the blaster.
√Pressure relief valves should be incorporated into the supply
system to minimize the risk from system over pressure.
√Anyone who will use the DF1400 should be trained in its basic
operation.
√The DirectFlo should always be turned OFF and vented prior to
performing any maintenance.
√When replacing parts during maintenance, use only Comco parts
and verify that all installations are correct before using the
DirectFlo.
Improper set-up or use of the DirectFlo DF1400 may result in a condition that could be
hazardous. All fittings and covers must be properly installed and tightened in order to
minimize any hazard.

Comco Inc. vi Issue Date: January 2009
Working with an Electrical Device
The electrical hazards associated with the DirectFlo are minimal, since all
primary electrical components are inside the primary housing. However, the
operator should take precautions that apply to any electrical device that has a
power cord that plugs into an electrical outlet. These precautions include:
√Verify the proper operating voltage on the DirectFlo by checking
the voltage select switch located on the back of the unit.
√Before plugging the power cord into an electrical outlet, examine it
for evidence of damage such as cracked, worn, or torn insulation;
exposure of bare wires; or bent tines on the plug.
√Ensure that the machine is never operated near water or while it is
wet.
√Always verify that the power switch is in the OFF position when
the machine is not in use for long periods of time.
When working inside the DirectFlo housing, there is the possibility of electrical
shock. To minimize this hazard, Comco recommends the following:
√Unplug the unit from facility power any time the machine’s cover
will be removed.
√Do not operate the DirectFlo with its cover removed.
√Keep the interior of the DirectFlo clean of dust, powder, and any
foreign object or substance that could conduct electricity.
CAUTION: Some abrasive powders are conductive
and may present a hazard if allowed
to accumulate inside the machine.
Working with the Abrasive Media
The DirectFlo uses several types of abrasive media that should not be inhaled or
ingested in large quantities or maintained in prolonged contact with the skin.
When working with the abrasive media, Comco recommends the following:
√Do not direct the abrasive blast on bare skin or face/eyes.
√A WorkStation and dust collector must be used in conjunction
with the DirectFlo. If you must blast outside a WorkStation, a full
facemask and oxygen supplied respirator and hand protection are
required per NIOSH (National Institute for Occupational Safety
and Health).
√Handling operations such as repackaging or refilling of the
abrasive media should only be performed in well-ventilated areas
and with proper care to minimize dust in the eyes or breathing
passages. Always use a dust respirator for dust protection when
exposed to dust clouds. The 3M respirator #8710 is NIOSH/MSHA
approved for these types of abrasive handling operations

Comco Inc. vii Issue Date: January 2009
Working with the Abrasive Media (cont’d)
√Certain abrasive media, such as glass beads, can present a
slipping hazard if they are spilled on the ground. Always clean up
spilled abrasive, and place appropriate warning signs in areas
where the abrasive will be on the ground (such as during long-
term operation).
√Abrasive powders, particularly glass beads and plastic, may
generate static charges. To minimize the risk of electrostatic
discharge, ground the DirectFlo and the WorkStation. In some
instances the operator may also wish to use grounding straps
(Wrist-Stats™ or equivalent).
√Flammable powders, such as walnut shell and plastic, may pose a
fire or explosion hazard. Always use a vigorous dust extraction
device to prevent hanging dust clouds.
√After using the DirectFlo, or after handling any of the abrasive
media, wash your hands before touching or rubbing your eyes.
√Gloves may be necessary for operators who are sensitive to
powders or dust on their skin.
√Some powders, if allowed to collect inside the machine, may
cause electrical shorts.
Material safety data sheets (MSDS’s) for all abrasives distributed by Comco are
available from the Comco factory. Every powder shipment includes an MSDS.
Contact the Comco Customer Service department to obtain extra copies of any
MSDS.
Avoiding Hazards Associated with Operating Machinery
√Place the DirectFlo securely on a solid workbench or counter so
that the unit cannot tilt or fall over.
√Always secure the nozzle-end of the abrasive blast hose before
pressurizing a blasting unit. An unsecured hose may whip around
and cause injury or damage.
√Keep fingers out of the hose pinch.
√When working inside the cabinet, avoid possible sharp edges and
remember that solenoids on valves can become hot.
√Set up the DirectFlo and WorkStation so that it is ergonomically
correct to allow safe and comfortable use by all operators.
√Route the foot pedal cord from behind the bench to prevent it from
becoming a possible trip hazard.

Comco Inc. viii Issue Date: January 2009
Avoiding Hazards Associated with Operating Machinery (cont’d)
The following warning labels/pictograms are utilized in the DirectFlo CE
(European) versions:
Symbol
Meaning
ELECTRICAL HAZARD
HAND PROTECTION RECOMMENDED WHERE
APPROPRIATE
EYE PROTECTION RECOMMENDED WHERE
APPROPRIATE
RESPIRATORY PROTECTION RECOMMENDED
WHERE APPROPRIATE

DirectFlo DF1400 Chapter 1: The DirectFlo 1400
Comco Inc. 1-1Issue Date: January 2009
Chapter 1: The DirectFlo DF1400
In This Chapter
A general description of the DirectFlo
How the DirectFlo works
Detail specifications

DirectFlo DF1400 Chapter 1: The DirectFlo 1400
Comco Inc. 1-2Issue Date: January 2009
STANDARD
HIGH CAPACITY
Overview
The Comco DirectFlo Model DF1400 is a bench-top machine that delivers a precisely
controlled stream of micro-abrasive particles at high velocity. With the appropriate
abrasive powder and the necessary adjustments, it will clean, deburr, cut or drill any
material, particularly hard or brittle ones. Since dry air is used as a propellant, it is a
relatively clean process.
The machine is essentially simple and uncluttered (see Figure 1-1). It consists
principally of an inlet air valve (rear panel), air pressure regulator with gage, modulator
(internal), abrasive powder tank, and mixing chamber. The abrasive PowderGate®
valve assembly to stop and start the abrasive flow, the footswitch to actuate it, and a
handpiece that holds the precision nozzle, complete the machine. All the component
parts are manufactured to the highest standards and are designed for maximum life
consistent with reasonable cost. The basic mechanisms employed, particularly the
modulator, are covered by the following patents:
United States: 3,053,016 Johnson
3,084,484 Hall
3,638,839 Weightman
United Kingdom: 1,243,294
Additional United States and foreign applications for patents are pending.
Figure 1-1: The Comco DirectFlo DF1400