Safe-man Prductivity System Mdel: Safe-man 3.0 Spnge-Jet, Inc. 14 Pattersn Lane, Newingtn, NH 03801 USA +1-603-610-7950 / www.safemansystem.cm Safe-man 3.0 User Manual - 19 June 2012
Table f Cntents Sectin Page 1.0 Intrductin 3 2.0 Safety Checklist 5 3.0 Requirements 6 4.0 Installatin 7 5.0 Operatin 13 6.0 Maintenance 16 7.0 Trubleshting 18 Ntes 19 IMPORTANT NOTE: While parts, systems, cmpnents, peratinal prcedures may be the same between equipment mdels, the images prvided in this manual may vary frm mdel t mdel. This manual represents the fllwing mdels: Safe-man 3.0c English Language is Original Instructins. Translated frm Original Instructins. Safe-man 3.0 User Manual - 19 June 2012
1.0 Intrductin Basic Cmpnents 1 1: Cntrl Panel 2: Nzzle Hlder (nt included) 2 3: Cntrl Pad 4: Nzzle (nt included) 5: LED Light Assembly 6: Prtective Lens Cver 7: Munting Screw 4 8: O-Ring 9: Green Tubing 10: In-line Deadman 11: Neprene Sleeve 3 5 12: Twinline 13: Grilla Cable (extensins sld separately) 14: Tuch Screen Display 15: Cntrl Panel Pwer Mains Plug 5 6 9 10 12 11 13 14 15 7 8 Safe-man 3.0 User Manual - 19 June 2012 Page 3 f 19
Cntrl Panel (right side view) 16 Basic Cmpnents (cntinued) 16: Cntrl Panel (right side view) 17: Mains AC Pwer Scket 18: Deadman Cntrl Scket 17 18 Cntrl Panel (left side view) 19 19: Cntrl Panel (left side view) 20: Cntrl Panel (inside view) 21 23 ABRASIVE CONTROL: 21: Supply Air - (Optin fr nn-spnge-jet equipment) 22: Signal Air - (Optin fr nn-spnge-jet equipment) 22 24 DEADMAN CONTROL: 23: Supply Air 24: Signal Air Abrasive Cntrl 20 Cntrl Panel (inside side view) 25: Deadman Cntrl Slenid Valve 26: Abrasive Cntrl Slenid Valve 25 26 Safe-man 3.0 User Manual - 19 June 2012 Page 4 f 19
2.0 Safety Checklist This Unit cntains electrical and pressurized cmpnents which cntrl a pressurized system. Only trained peratrs shuld adjust, maintain and repair it. Be sure t bserve all applicable safety requirements frm the blast unit manufacturer as well as industrial, lcal, state/prvince and gvernment regulatins. Inbund pressure shuld never exceed 7bar (100psi). Operatrs and peple in prximity t blasting shuld always wear eye and hearing prtectin with apprpriate respiratry equipment and clthing, which may depend n the type f cating r cntaminant being remved. Imprper cnfiguratin and installatin may cause unintentinal start-up and can result in persnal injury. Cntact Spnge-Jet Technical Services at techservices@spngejet.cm/+1-603-610-7950 fr assistance. This unit is nt designed t perate in heavy rain, snw r temperature extremes. Safe-man 3.0 User Manual - 19 June 2012 Page 5 f 19
3.0 Requirements 3.1 Equipment Requirements _ Safe-man Systems are designed t perate with Spnge-Jet Feed Unit s and ther cnventinal abrasive blast vessels. Unit functinality depends n functinality f the abrasive blasting vessel. This unit is designed t perate up t 91m (300 ft) frm the abrasive blasting vessel. This unit prvides three basic functins: LED Nzzle Light In-line Deadman; functins as n/ff cntrl f blast vessel OR Blast mde setting switches between blasting with air nly (air wash) and blasting with air and abrasives (nrmal blasting). TO UTILIZE THIS FUNCTION, THE ABRASIVE BLAST VESSEL MUST HAVE THIS PNEUMATIC CONTROL FEATURE. NOTE: all Spnge-Jet Feed Unit mdels have this feature. 3.2 Pwer Requirements _ This unit is designed t perate using an AC pwer supply. AC perating range is 100-240 vlts, 50-60Hz (80watts) Fr use in areas withut pwer, an autmtive inverter cnnected t a cmpressr battery is cmmnly used. Safe-man 3.0 User Manual - 19 June 2012 Page 6 f 19
4.0 Installatin 4.1 Cnnect Pwer Crd _ 4. 1 4.2 Cnnect Grilla Cable _ 4 4.3 Cnnect Twinlines _ 4 4.4 Remve Items frm Inside Safe-man _ Safe-man 3.0 User Manual - 19 June 2012 Page 7 f 19
4.5 Cnnecting Cntrl Panel (In-line Deadman Valve) _ Cnnect yellw twinlines where pneumatic Deadman typically cnnect. If system architecture and fittings are nt the same, see sectin 4.7 Cnnecting Cntrl Panel (Custmized Cnnectin). 1 2 (Spnge-Jet Mdels ONLY) 4.5 Cnnecting Cntrl Panel (Abrasive Cntrl Valve) _ Figure 1 Feed Unit Set-up Schematic Feed Unit Cntrl Panel New Green Pneumatic Tubing (cut each sectin t length) Old Green Pneumatic Tubing Discnnect frm fittings at bth ends and leave in place. Feed Unit Air Mtr Safe-man Cntrl Panel New Yellw Twinline (frm Safe-man Cntrl Panel) Green Grilla Cable Old Yellw Twinline & Deadman Discnnect and stre fr trubleshting Safe-man Cntrl Pad Safe-man 3.0 User Manual - 19 June 2012 Page 8 f 19
Fr Spnge-Jet Mdels ONLY 1. Lcate Green Tubing which cnnects t Feed Unit Auger Mtr 2. Discnnect Green Tubing; d nt discard 3. Fllw Green Tubing t Feed Unit Cntrl Panel, discnnect it; Hw t Discnnect Pneumatic Tubing 4.6 Cnnecting Cntrl Panel (Abrasive Cntrl Valve) _ (cntinued) Cntrl Panel Feed Unit Air Mtr Feed Unit Cntrl Panel Green Pneumatic Tube 1 Replace ld Green Tubing with new Green Tube Cut new Green Tubing t needed length Press tube dwn 2 Hld return ring dwn 3 Insert leftver new Green Tubing int Signal Air fitting f Abrasive Cntrl Slenid Valve f Safe-man Cntrl Panel Insert new Green Tubing frm Feed Unit Cntrl Panel int Supply f Abrasive Cntrl Slenid Valve n Safe-man Cntrl Panel Insert the ther end f new Green Tubing int fitting that leads t Feed Unit Auger Mtr Pull tube ut Cut excess Green Tubing if desired Safe-man 3.0 User Manual - 19 June 2012 Page 9 f 19
4.7 Cnnecting Cntrl Panel (Custmized Cnnectin) _ The Safe-man cntrls pneumatic slenid valves which send signals t the blast vessel. Slenid valves can be custmized t accmmdate a variety f signal requirements. This unit is factry-cnfigured t wrk with Spnge-Jet Feed Units and wrks with mst ther units. Use Figure 2 t match the air signal functin t the desired functin f yur blast vessel. Figure 2 Safe-man Slenid Schematic (Safe-man Back View) Deadman Slenid Abrasive Shut-ff Slenid Cntrl D2 (typically plugged) ~ Air Relief ~ (Bleed) = ~ Cntrl M2 (typically plugged) Cntrl D1 ~ ~ Cntrl M1 Supply Deadman Slenid In-line Deadman Functin Cntrl D1 (Installed frm Factry) Cntrl D2 (Plugged frm Factry) Activated / ON Blast Mde Air Signal N Air Signal Deactivated / OFF Nt Blasting N Air Signal Air Signal Shut Dwn (n pwer) N Air Signal Air Signal Abrasive Shut-Off Valve Cntrl Pad Mde Cntrl M1 (Installed frm Factry) Cntrl M2 (Plugged frm Factry) Abrasive Air Signal N Air Signal N Abrasive N Air Signal Air Signal Shut Dwn (n Pwer) N Air Signal Air Signal Safe-man 3.0 User Manual - 19 June 2012 Page 10 f 19
4.8 Assembling Cntrl Pad and In-line Deadman _ NOTE: Adjust Safe-man Neprene Sleeve t lay flat. NEVER lcate In-line Deadman n inside curve f blast hse CAUTION: Never use Safe-man when In-line Deadman has severe creases r flds. This cnditin can uncntrllably activate blasting. 2.5cm (1in) Optinal - fr infrequent nzzle changes Safe-man 3.0 User Manual - 19 June 2012 Page 11 f 19
4.8 Assembling Cntrl Pad and In-line Deadman (cntinued) _ T Safe-man Cntrl Pad T Safe-man Cntrl Panel + + One end f Grilla Cable plugs int Safe-man The ther end f Grilla Cable plugs int Grilla Cable leading t Safe-man Cntrl Pad. Nte: additinal Grilla cable extensins can be added as needed. Safe-man 3.0 User Manual - 19 June 2012 Page 12 f 19
5.0 Operatin Befre Operating the Safe-man: Verify the Feed Unit (r abrasive blast unit) is prperly setup and perating crrectly as directed by manufacturer. Verify that unit is secured in an apprpriate manner fr peratin. Inspect all Blast Hses and cnnectins. Repair r replace wrn r damaged cmpnents. Ensure all cuplings are equipped with cupling gaskets, safety pins and hse restraints and all are prperly installed. Insure blast vessel, its hses and Safe-man are prperly grunded. Figure 2 Safe-man Cntrl Panel Operatin BLAST: Indicates Air and Abrasives are exiting the Nzzle AIR ONLY: Indicates Air nly is exiting Nzzle WARNING: AIR ONLY mde can still prduce the presence f sme abrasives material exiting the nzzle. STANDBY: Indicates neither Air nr Abrasives and Air are exiting the nzzle NOZZLE: Indicates Cntrl Pad is nt prperly cnnected Safe-man 3.0 User Manual - 19 June 2012 Page 13 f 19
Upn cnnecting pwer t the system, the LCD display will illuminate green in Standby Mde (Image 1) cnfirming prper cnnectin - and the Cntrl Pad and Cntrl Panel have successfully cmmunicated. If there is a failure f cmmunicatin, the Cntrl Panel LCD will illuminate red and read Safe-man Nt Cnnected (Image 2). 1 2 Once in Standby Mde the system is nly cntrlled using the Cntrl Pad munted at the nzzle. In additin t Images 1 and 2, images 3 and 4 are indicated n the Cntrl Panel LCD. 3 4 5 NOTE: Manipulatin f the Cntrl Pad must fllw a specific sequence intended t prevent unintentinal startup. All initiatins and changes must ccur while the In-line Deadman is depressed. if nt the system will autmatically shut dwn. 1. T initiate Air and Media Blasting Mde (Image 5), hld the Inline Deadman and simultaneusly depress the Green Safety Switch 2. T initiate Air Only Mde while blasting (withut a full shutdwn) remain in cnstant cntact with the Inline Deadman and depress the Red Mde Buttn nce, within ne secnd depress the green safety switch. If the green safety switch is nt depressed within ne secnd the system will shut dwn. Nte: All Mde Changes will be reflected in a change in the LCD display. WARNING: AIR ONLY mde can still prduce the presence f sme abrasives material exiting the nzzle. Safe-man 3.0 User Manual - 19 June 2012 Page 14 f 19
Figure 2 Safe- man Cntrl Pad Operatin Green Safety Switch = and Indicatr Light Indicatr lights In-line Deadman = Cnnectin t a pwered cntrl bx = Indicatr lights = Air Only Mde = Air and Abrasives Mde Red ON/OFF Mde Switch = = Blast Mde Activated - Tggles Abrasive Cut-ff Valve ON/OFF. - Als deactivates Deadman (Off). USING THE CONTROL PAD As a Deadman MODE + Press and Hld t Blast Press and Release (Green Safety) Press Switch and Release; tggles between ON/OFF f abrasive shut-ff valve Safe-man 3.0 User Manual - 19 June 2012 Page 15 f 19
6.0 Maintenance Rutine maintenance is required t prvide lng and reliable equipment life. This Unit must be shut dwn and discnnected prir t cnducting maintenance. Prir t each use: _ Inspect all hses, cables, cnnectins and buttns fr excessive r abnrmal wear and damage. Inspect Prtective Lens Cver fr damage. Safe-man 3.0 User Manual - 19 June 2012 Page 16 f 19
Adjustment f In-line Deadman Shut Off Delay: _ The peratr can delay time frm when the In-line Deadman is released t when it signals fr shutdwn (t the Cntrl Panel). Nte: the default setting is (0) which represents an immediate transitin frm lss f cntact t shutdwn initiatin. Fr usage cnditins where cntact culd be interrupted, but cntrl nt lst, this delay can be increased: T change the In-Line Deadman Shutff Delay 1. Frm STANDBY Mde tuch the DELAY SETUP (Image 1) 2. See current setting (in this case 0 ). Tuch 0 (Image 2) which will display a keypad (Image 3) 3. Enter desired Deadman Shutff Delay time using the key pad (single digit nly) up t a maximum 9 4. Once the number is selected, tuch the Enter key r (Image 4, figure 4a) and then tuch MAIN (Image 4, figure 4b) 5. STANDBY MODE will display and the change has been made (Image 5) 1 2 3 4 5 4b 4a Safe-man 3.0 User Manual - 19 June 2012 Page 17 f 19
7.0 Trubleshting N nzzle utput when depressing In-line Deadman and triggering (press and release) Green Safety Buttn LED Nzzle Light dims, shuts ff r blinks slwly Cnfirm that Main Air Ball Valve n Spnge-Jet Blasting Unit is pen. Cnfirm that Emergency Stp Buttn n Spnge-Jet Blasting Unit is in the Run Psitin. Cnfirm Cntrl Panel is nt displaying a red SAFEMAN NOT CONNECTED LCD readut indicating a lse r fully discnnected Grilla Cable. This is nrmal peratin, IF Safe-man has been sitting withut air flw frm blasting. T remain cl (in absence f air flw) LED Nzzle Light shuts dwn intermittently - prtecting it frm verheating. This feature intervenes at 145 F (62.7 C) and shuts ff until cl at 150 F (65.5 C) If LED Nzzle Light flashes during blasting and the nzzle is munted prperly at end f the nzzle, inspect fr lse cnnectins t light. Safe-man 3.0 User Manual - 19 June 2012 Page 18 f 19
NOTES: MODEL#: SERIAL#: Safe-man 3.0 User Manual - 19 June 2012 Page 19 f 19