abrasive system - accustream · 2015-09-03 · accustream cutting systems 1 13095 abrasive...

ABRASIVE SYSTEM ABRASIVE REGULATOR II 800# BULK ABRASIVE DELIVERY POT

13095 Abrasive Regulator II and 800# Pot Manual

TABLE OF CONTENTS

Contact Information and Customer & Technical Service ......................................................................... 1

1 Introduction ............................................................................................................................... 1 2 Abrasive Regulator.................................................................................................................... 1

Description:............................................................................................................................................... 1 2.1 Regulator Installation.................................................................................................................... 2

Location .................................................................................................................................................... 2 Attaching the Regulator to the Machine ................................................................................................... 2

2.2 Connecting the Metering Regulator............................................................................................. 3 Abrasive Delivery from the Pot to the Regulator...................................................................................... 3

2.3 Regulator Startup .......................................................................................................................... 4 Metering Regulator Flow Rate.................................................................................................................. 4 Moisture or Water ..................................................................................................................................... 5 Disassembly and Reassembly ................................................................................................................... 6

3 Bulk Abrasive Delivery Pot ...................................................................................................... 7 Additional features .................................................................................................................................... 7

3.1 Abrasive Pot Installation............................................................................................................... 8 3.2 Abrasive Pot Operation................................................................................................................. 8

Startup: ...................................................................................................................................................... 8 Refilling the Abrasive pot ......................................................................................................................... 9

4 Troubleshooting....................................................................................................................... 10 5 Drawings and Parts Lists........................................................................................................ 11


AccuStream Cutting Systems 1


Contact Information and Customer & Technical Service At AccuStream, your purchase is only the beginning of our commitment to help you succeed. We believe that what happens after the sale is just as important as what happens before. Customer Service Representatives are available to take your calls Monday through Friday 7:00 AM to 5:00 PM CST. If you need service after-hours AccuStream is also on-call 24 hours a day, 7 days a week to ensure your system is up and running around-the-clock. For more information, please call Customer Service toll-free at 866-566-7099.

1 Introduction The AccuStream Abrasive Regulator II is used in the Abrasivejet cutting process. The Regulator will deliver a steady supply of abrasive material to the cutting head system. A metering system allows the operator to control the amount of abrasive needed for each process.

2 Abrasive Regulator

Description: The Abrasive Regulator is positioned over the cutting head and is fed abrasive from the abrasive delivery pot. The Regulator will provide an accurate metering and control of the abrasive flow rate. The regulator uses an air cylinder to turn the abrasive flow to the cutting head ON or OFF. An adjustment control knob is used to meter the abrasive rate to the cutting head.



2.1 Regulator Installation

Location The Metering Regulator is mounted to the Z-axis faceplate over the cutting head at up to 6’ (feet) from the floor level. This should be high enough to keep the regulator out of the spray-back area from the cutting head and within reach for adjusting the abrasive flow rate. NOTE: Use the over-all height of the assembled regulator to determine the amount of space needed before mounting.

Attaching the Regulator to the Machine 1. Remove the two screws that attach the mounting plate to the regulator. Use the mounting plate

to position and drill mounting holes on the machine. NOTE: The holes on the mounting plate are positioned 2.5 inches (63.5 mm) on center from each other and counter bored for .25 (6.35 mm) Capscrews.

2. Reassemble the back mounting plate to the regulator. 3. Remove the bottom adapter from the regulator and thread the rear tie rod upward so that there is

access to mount the regulator to the machine. Use ¼” (6 mm bolt) cap screws for mounting the regulator.

4. Re-thread the tie rods back into their original locations.



2.2 Connecting the Metering Regulator Items needed:

• Requires: 60-80 psig incoming compressed air. • 3/8” OD x 1/4” Polyurethane tubing. • 1/4” OD nylon or polyethylene tube to connect the regulator air cylinder to the solenoid valve • 4 way spring return directional solenoid valve. This is needed to pressurize the abrasive on/off

air cylinder in both directions.

1. Connect the 4-way valve connections to the 2 (two) fittings on the air cylinder. When the solenoid valve is de-energized or abrasive switch is in the off position, the regulator will be OFF.

2. Connect the N/O valve fitting (with air pressure) to the inside fitting on the air cylinder see.

3. Turn the abrasive switch on/off with abrasive in the regulator’s acrylic tube to verify that the regulator valve operates properly.

4. Connect the 3/8 tube into the bottom outlet tube of the regulator.

Abrasive Delivery from the Pot to the Regulator

• The hose from the pot to the metering regulator should have a minimum of elevation changes. A maximum hose height of 10’ (feet) from the floor is usually sufficient.

• The hose should not be more than two feet above the top of the metering regulator to ensure even flow.

• A 90-degree fitting should be used at the top of the Regulator. • Hose end connections should be with brass barb fittings and hose clamps to prevent the hose

from blowing off the fittings.

If using more than one regulator • Use ONE hose from the pot to a location near the regulators. • Split the flow so that the multiple hoses provide equal resistance to flow.

NOTE: When feeding multiple regulators from ONE pot, the paths to each regulator must be

close to the same length so each regulator will receive the same flow of abrasive. Different hose lengths after the split will cause uneven abrasive pressure on the regulators. This can cause different abrasive flow rates between the regulators.



2.3 Regulator Startup Before the startup, check that the Regulator is installed correctly and all hose connections are in place with the hose clamps tightened.

1. With the pot pressure valve OFF attach the compressed air line to the pot. 2. Verify that the Abrasive Regulator is turned OFF 3. Set the pot air regulator pressure to 40 psi. 4. Fill the pot with at least 500# of abrasive or until full. 5. Turn the pot pressure to ON. 6. With lines from the pot empty turn the regulator ON

The abrasive will initially feed from the pot unevenly until the air in the feed hose is replaced with abrasive. When the line becomes stable (full of abrasive), there will be no flow unless the abrasive metering regulator is turned on. For longer delivery lengths, the pot pressure may need to be increased to a maximum of 80 psi to accommodate for the additional length.

NOTE: If the abrasive flows after turning the regulator OFF do not plug the top of the metering regulator top vent. The top vent elbow is necessary for venting.

Metering Regulator Flow Rate The abrasive flow rate coming from the Metering Regulator can be adjusted by turning the Metering Control Knob. The knob settings change the size of the hole in the metering aperture (right). The adjustment knob is marked in one-quarter graduations starting at 1 and going to 10. *Any over travel, in either direction beyond the 1 and 10 markings on the adjustment knob is normal and will not effect the metering rate adjustment settings. The abrasive flow rate can be, adjusted during cutting. The Abrasive Regulator includes a pneumatically controlled on-off gate to turn the abrasive flow on and off.

Abrasive Settings The Control Knob Setting chart is based on 80HPA garnet and gives the abrasive flow rates that can be set by adjusting the knob settings. Actual rates may vary slightly due to abrasive grit size and the feed pressure into the regulator acrylic tube. Suggested Set Points: Combination Set point 9/30 5 10/30 6 1340 7 2/3 15/40 8 1/3



If the abrasive flow does not stabilize due to air bubbles in the hose and puffing at the top of the regulator:

• Make sure that the pot is full of abrasive. Low abrasive content will allow air to push through the abrasive and cause a bubbling effect in the abrasive delivery hose.

• Make sure there is at least the minimum of abrasive feed elevation going into the top of the regulator and that there is a ½” elbow on the top inlet of the regulator.

• Check to see if the abrasive has clumped inside the pot. Clumped abrasive will let air pass through the abrasive. Discharge the contents of the pot into clean containers. Pour the emptied dry abrasive through a window screen and back into the pot.

• If there is moisture in the abrasive, it should be discarded. Verify that the air pressure regulator bowl on the pot is emptied of water.

Moisture or Water When the nozzle is plugged, water will go up the feed hose to the regulator and discharge from the vent hole on the back of the Output Adapter. If this occurs, the Adapter will need to be cleared. With the jet ON and the Regulator OFF, plug the back VENT hole (right). This should vacuum any moisture and abrasive from the Adapter.

If the abrasive still does not flow: 1. Disconnect the regulator hose from the cutting

head. 2. Loosen the 2 (two) thumbnuts that connect the

Regulator Base to the regulator. 3. Lower and turn the base (Right). 4. Hold the open end of the hose over the tank and

blow the contents of the regulator base into the tank until regulator base bowl and hose are dry.

5. Reconnect the regulator base and hose. Any moisture reaching the regulator, from piercing should be minimized. It is best to use a splashguard on the nozzle.



Disassembly and Reassembly The valve and metering area of the regulator should not normally require maintenance. In the event that this area does require disassembly, the orientation of the parts during reassembly must be correct. On the assembly drawing cut-out, (right) note the location and thickness of Sandwich plate and the Exit plate. The 0.50 dimensions and plate thickness will determine the orientation and placement of both parts.



3 Bulk Abrasive Delivery Pot Description The Bulk Abrasive Delivery Pot has a capacity of 800# of garnet abrasive. The Pot stores the abrasive and feeds it to the abrasive regulator. The pot is rated at 125 psig and there is a safety relief valve on the inlet air preset for 100 psig. The pot holds the cutting abrasive under pressure and uses the air pressure to push garnet abrasive through ½” or ¾” ID delivery lines to the metering regulator. During normal use, the pot pressure should not exceed 80 psig. A manual three-way valve is used to pressurize and discharge pressure from the pot. This valve is mounted on the side of the pot near the top. The pot is pressurized by turning the valve lever and lifting the pop-up valve handle at the top center of the pot while compressing the air in the pot. Turning the valve lever to the opposite position will discharge the pressurized air in the pot through the muffler.

Additional features Filling Screen The top of the abrasive pot contains a removable filling screen to help in breaking up bulk abrasive while it is being poured into the pot.

Maintenance Cover The maintenance cover allows access to the interior of the pot for regular maintenance and cleaning.

Low-level Sensor The Low-level sensor detects the abrasive level in the pot and warns the operator with a sensing light when the abrasive level gets too low



3.1 Abrasive Pot Installation Location The pot location should provide an access for abrasive loading near one of the front legs of the cutting machine. Position the Pot close to the work area where it can stay dry.

Abrasive Delivery from the Pot to the Regulator • Requires: 60-80 psig compressed air. • 1/2” to 3/4” ID x 0.140 wall braid reinforced PVC tubing 150 psi rated. • Gear-type hose clamps

NOTE: To prevent the hosing from blowing off the fittings, hose end connections should be made with brass barb fittings and hose clamps.

A 90-degree fitting should be used going into the top of the Abrasive Regulator. The PVC hose is flexible and can pass through a cat-track on the swivel elbow or suspended from the high-pressure whip. The hose coming down to the metering regulator should have a minimum of elevation changes. A maximum hose height of 10’ from the floor is usually sufficient. The hose should not be more than two feet above the top of the metering regulator to ensure even flow. Maintaining a delivery line length of less than 50’ (feet) is ideal.

3.2 Abrasive Pot Operation

Startup: Before startup, check to make sure that the Pot and Regulator are installed correctly with all hose connections in place, and the hose clamps tightened.

1. With the pot pressure valve OFF, attach the compressed air line to the pot. 2. Verify that the Abrasive Regulator is turned OFF. 3. Verify that the regulator pressure on the pot is set to 40 PSI. The pot pressure may need to be

increased to a maximum of 80 psi to accommodate longer delivery lengths. 4. Plug the cord from the pot low-level sensor box into an 115V outlet. 5. Fill the pot with at least 200# of abrasive or until the low-level sensor light turns off. 6. Pressurize the abrasive pot by turning the three-way valve lever to OPEN while PULLING UP

on the pop-up valve. The pop-up valve is attached to a ball handle that is located at the top center of the pot.

Three-way Valve Pop-up Valve



NOTE: There should not be any abrasive flowing until the abrasive metering regulator is turned on.

Refilling the Abrasive pot The pot can be filled manually from small bags or from bulk containers. When the contents of the pot are low, the low-level sensor light will turn on. At the next reasonable stop, point the operator should halt cutting and discharge the pot pressure before any new abrasive is poured in through the top of the pot. After the refill is complete, the pot must be re-pressurized before the cutting starts.

NOTE: To prevent large particles from entering the pot and possibly plugging the nozzle, a window screen can be placed over the perforated metal screen at the top of the pot. This will serve as a last-chance filter

NOTE: Regularly check for water in the air regulator bowl and empty it if necessary using the bottom valve. If the bowl fills up with water, the pot abrasive will get wet and abrasive will not feed. If this happens, the pot contents will have to be dumped and the pot interior dried out.

Low-level sensor The low-level sensor is factory adjusted for sensing the garnet abrasive level in the pot. If the sensor is not working properly, it can be adjusted with the potentiometer screw. Adjust the sensor so that the light turns OFF after the abrasive just covers it inside the pot. Running the pot contents down too far will cause an unstable abrasive flow.



4 Troubleshooting Problem Solution

Contaminates such as wire and paper may have gotten into the pot a blocked the bottom exit. Discharge all pressure in the pot, remove the side access cover, clean, and inspect the interior and bottom of the pot. Make sure that the pot is close to full of abrasive. Low abrasive content will allow air to push through the abrasive and cause a bubbling effect in the abrasive delivery hose. Make sure there is a minimum of abrasive feed elevation drop to the top of the regulator and that there is a ½” elbow on the top inlet of the regulator.

Abrasive flow does not stabilize or flow at startup.

If the problem persists, empty the abrasive from the pot using the delivery hose with the pot under pressure. If the abrasive on top of the screen has moisture, the pot contents should be discarded.

Moisture or water in the abrasive.

Discharge the contents into a clean container through a window screen. If the pot contents have no moisture, pour the abrasive back into the pot. The act of emptying and refilling the pot can improve the abrasive delivery. Do not plug the top of the metering regulator. The top vent is necessary for venting.

Abrasive flows after turning the regulator, off:



5 Drawings and Parts Lists

Abrasive Pot Callout list

ITEM QTY P/N DESCRIPTION 1 1 11202 POT 6FT3 LOPOT 2 1 CL 02336 COVER PAINTED BLACK 3 1 CL 03100 SCREEN PAINTED BLACK 4 1 CL 05068 MUFFLER 5 1 POP-UP VALVE 6 1 MMC#4373K43 3-WAY 1" BRASS VALVE 7 1 11259 POP-UP VALVE STOP BAR 8 2 MMC#9489T41 EYE BOLT 9 1 MMC61095K54 BALL GRIP 10 1 B73G-2AK-QD3-RMG FILTER/REG W/ GAGE NORGREN

11 1 5203-06 BRACKET NORGREN 12 13 1 1 1/4 X 1/2 BUSHING - IRON 14 1 1/2 CLOSE NIPPLE - IRON 15 1 1/2 ELBOW - IRON 16 3 1" CLOSE NIPPLE - IRON 17 1 1" TEE - IRON 18 1 1" PLUG - IRON 19 1 1" ELBOW - IRON 20 1 1" X 1/4" BUSHING - IRON 21 22 1 BARB FITTING 1/2" MPT X 3/4" HOSE 23 1 KI 0203 LEVEL SENSOR EFFECTOR 24 1 U10004 WELL, LEVEL SENSOR EFFECTOR 25 1 AGC1 FUSE BUSS 26 1 HKP-HH FUSE HOLDER BUSS 27 1 2W687 CORD SET GRAINGER 28 1 2W934 RELAY SPST 29 1 142-011 PILOT LIGHT IDI 120V W FRICTION BACK ACME 30 1 PUSH BUTTON SP N-O MOMENTARY

abrasive system - accustream · 2015-09-03 · accustream cutting systems 1 13095 abrasive...

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