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Sponge-Jet medias change in size and density as they progress through their life
cycle, the ability to adjust and compensate for those changes are critical. The
designed components engineered into Feed Units allow for this compensation in
simple and mostly autonomous ways. We accomplish this through adjustment of the
Auger Speed/Media Feed Rate. Recommended pressures are listed on each unit.
Control Valve
Actuator
Air Motor
Timer
Good painting practices dictate that the profile should never exceed 50% of the primer
coat thickness. It is certainly mechanically sound to expect that bigger abrasive particles
will cut through a coating faster than will smaller abrasive particles. However one of the
items to consider though is with any abrasive smaller, finer, abrasive particles produce a
denser grouping and remove coatings or contamination more efficiently than do larger
abrasive particles. This can easily result in a larger abrasive requiring more dwell time to
produce equal cleaning results.
Being able to achieve these consistent readings is why Sponge-Jet medias are classified
and named utilizing specific numerical designations, S-120, S-30 S-16 or R-G40. This
tight sizing also helps limit the human error factors associated with media feed rate
settings or nozzle pressures.
Conventional abrasives are commonly sold in varying size ranges, Fine, Standard,
Course and Extra Course for example. While these ranges do produce both ends of the
speed and efficiency spectrum previously noted, they do as well provide the opportunity
to produce both inadequate and excessive profile results. Often times these blended size
combination are based on the lower, or expendable abrasives overhead cost limitations.
Utilizing a tight and consistent size of abrasive, results in a consistent and repeatable
profile generation. This condition is not only known to produce improved coating
performance, but is often times a noted and documented testing procedure, required for
the acceptance of the coatings process by both the owner and the paint suppliers quality
control standards.
As Sponge-Jet bonds multiple pieces of quality and tightly sized abrasive or cleaning
agents into each granule of Sponge media, even as multiple recycles of the media
are attained, the degraded material that separates from the granule is removed and
segregated by the Recycler unit, leaving only the appropriately sized abrasive
resident for the remaining blasting cycles. This helps assure that the profile
consistency remains at a high level from beginning to end of media lifecycle.
Air volume requirements are specific to the nozzle size utilized, balanced against
the desired blast pressure. Larger nozzle diameters require increased volumes of
compressed air to sustain desired pressures.
Current units utilize 2.0 inch piping components so as to have the lowest pressure
drop internally. Any reduction it the supply air fitting below this 2.0 inch diameter will
defeat this benefit and limit the system throughput to that size fittings capacity.
The smallest fitting or coupling supplied to the unit will ultimately determine the
success or failure of the required production regardless of the pressure the supply
source can produce.
2008 Sponge-Jet Inc. All rights reserved.
Components
Components
Moisture is removed automatically from
compressed air source by a Secondary
Moisture Separator.
It utilizes a 40 micron element as its
standard.
It is equipped with an automatic dump
mechanism to expel accumulated
moisture into an appropriate collection
device.
Components
After moisture is removed, the full volume
of supply air is held at the Main Air On Off
Valve until the operator depresses the
Deadman trigger on the hose.
Components
Once the Main Air On/Off Valve is
opened the air passes through the
Blast Pressure Regulator, which will
determine how much of the pressure
of the supply air is utilized.
Components
The operator determined Blast
Pressure is displayed on the Blast
Pressure Gauge and adjusted by the
Panel Mount T handle regulator below
it.
Components
Components
Media inside the vessel is fed out the
bottom of the vessel by a Media Actuator,
which is controlled by various valves and
timers on the back of the Control Plate.
This Media Actuator moves in 45 degree
back and forth segments (Nor Continuous
Rotation) and keeps the pressure in the
vessel from compressing the media to the
point of poor or no flow.
Components
Augers are intended to feed media into
the blast hose.
They control the volume of media, which in
turn manages dust and media
consumption.
They are durable units, but are the point
where any foreign matter allowed into the
reclaimed media is likely to lodge and
inhibit flow.
Components
The Auger is adjusted by the Media Feed
Regulator, which is mounted on the
control plate.
The pressure provided to the Auger is
represented on the Media Feed Gauge.
The recommended pressures are
suggested in the chart below the regulator
and gauge.
They are based on how many times the
media has been reused.
Components
Exhaust of the unit occurs when the
Deadman handle is released. Automatically
the unit vents any pressure inside the vessel
through the Exhaust System. This includes
the Exhaust Valve itself, the Exhaust
Muffler, which diffuses the escaping air and
catches any media that is ejected with this air.
The Exhaust System also houses an OverPressure Relief Valve, which will open
automatically if the inbound pressure in the
pot exceeds approximately 150 psi.
2008 Sponge-Jet Inc. All rights reserved.
Operational Overview/Summary
1. Assure a complete understanding of all Safety and Operational procedures before
pressurization or utilization of this equipment. Read and understand all manuals
thoroughly.
2. Attain and utilize per manufacturers instructions all PPE required based on the
specific activity, local and or other guidelines.
3. Confirm air supply valves are closed and Emergency Stop Systems are engaged.
4. Connect adequate sized supply (Bull) hoses and Blast hoses with safety pins and
hose restraints.
5. Charge the system with compressed air and assure it reaches and maintains the
pressure requirements for this activity.
6. Pressurize the system and adjust the Blast Pressure and Media Feed Rate to
desired settings, based on media type, lifecycle conditions and activity specific
requirements.
System Depressurization
1. Release the Deadman and allow the system to fully depressurize before
relinquishing control of the Deadman and Blast Hose.
2. Discontinue the supply of compressed air from its source.
3. With this supply confirmed as discontinued, with the Main Air Ball Valve of the
Feed Unit open and the Emergency Stop Button disengaged, activate the Deadman
Handle and expel any remaining pressure inside the Sponge-Jet Feed Unit.
4. Once all gauges read 0 psi, release the Deadman trigger, activate the
Emergency Stop Valve, close the Main Air Ball and disconnect the machine from
the compressed air supply source.
Course Complete