AXXIOM Manufacturing, Inc. SCHMIDT 0.9 Cu. Ft Operation And Maintenance Manual

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Mini Abrasive Blasters 0.5 – 0.9 cu. Ft (TVII)

OPERATION AND MAINTENANCE MANUAL

JULY 2013

SAVE THIS MANUAL AND MAKE AVAILABLE

TO ALL USERS OF THIS EQUIPMENT!

Manual Part Number 7200-265

(Available for downloading from schmidtabrasiveblasting.com)

IOM Manufacturing, Inc.

11927 S. Highway 6, Fresno, Texas 77545

800.231.2085 * 281.431.0581 * fax 281.431.1717

Visit us at www.schmidtabrasiveblasting.com

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Page 1 Mini Abrasive Blasters 0.5 – 0.9 cu. Ft (TVII) OPERATION AND MAINTENANCE MANUAL JULY 2013 SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL USERS OF THIS EQUIPMENT! Manual Part Number 7200-265 (Available for downloading from schmidtabrasiveblasting.com) IOM Manufacturing, Inc. 11927 S. Highway 6, Fresno, Texas 77545 800.231.2085 * 281.431.0581 * fax 281.431.1717 Visit us at www.schmidtabrasiveblasting.com...
Page 2 WARNING 1. Any person intending to operate this equipment or any person intending to be in the vicinity during its operation must receive proper training from his/her supervisor, employer and/or supplier. If this equipment is to be leased or rented, the supplier must assure that the lessee or renter has received proper training before the lessee or renter takes possession of the equipment.
Page 3 Instructions for use of manual sections This manual contains information needed to operate and maintain a Schmidt® Abrasive Blaster. Read this entire operations and maintenance manual before using the abrasive blaster. Pay close attention to the Rules for Safer Operation (Section 1.0), and the Dangers, Warnings, and Cautions identified. The purpose of safety symbols and explanations are to alert operators of the possible hazards and explain how to avoid them.
Page 4: Warning Decal Identification And Location
Warning Decal Identification and Location Listed below are the warning decals and the corresponding hazards related to this equipment. Refer to Figure 0.1(a) and 0.1(b) for images of the warning decals. Refer to Figure 0.2(a) and 0.2(b) for the locations of these warning decals on the abrasive blaster. Qty.
Page 7: Table Of Contents
Table of Contents Section Page Warning Decal Identification and Location Rules for Safer Operation Specifications and General Information Installation Requirements and Personal Protective Equipment Abrasive Blast System General Operation Mini Blast System General Operation Pre-operation Procedures Operating Instructions Maintenance and Inspection Instructions Drawings and Parts Lists 10.0 Recommended Spare Parts Lists...
Page 8: Rules For Safer Operation
Rules for Safer Operation 1.1. GENERAL RULE FOR SAFER OPERATION. SCHMIDT® ABRASIVE BLASTERS HAVE BEEN DESIGNED TO BE SAFE WHEN USED IN THE PROPER MANNER. ALL ABRASIVE BLASTERS ARE POTENTIALLY DANGEROUS IF ALL SAFETY PRECAUTIONS ARE NOT RIGOROUSLY FOLLOWED. PROPER TRAINING IS REQUIRED BEFORE OPERATION. PROPER PROCEDURES MUST BE FOLLOWED.
Page 9 1.5. PROTECT YOUR EYES. Do Not operate this equipment without wearing OSHA approved safety glasses. Observe all applicable local, state and federal safety regulations. See Section 3.10 and OSHA 29 CFR 1910.133. When filling the blast vessel and during the blast operation, abrasive can be blown in the face and eyes of operators.
Page 10 1.8. PROTECT YOUR HEARING. Do Not operate this equipment without wearing OSHA approved hearing protection. Observe all applicable local, state and federal safety regulations. See Section 3.10 and refer to OSHA 29 CFR 1910.95. Loud noise is produced by the blast nozzle and the blowdown operation of this equipment. All operators and personnel in the vicinity must wear OSHA approved hearing protection during the operation of this equipment.
Page 11 1.17. AVOID DANGEROUS ENVIRONMENTS. Do Not operate this equipment in elevated areas without using fall protection equipment. Certain applications of this equipment may require the use of scaffolding. Use of scaffolding creates hazardous situations such as tripping and fall hazards which can result in serious injury or death to operating personnel.
Page 12 1.25. ASME NAMEPLATE REQUIRED. Do Not operate this equipment if the ASME pressure vessel nameplate is missing. Contact Axxiom Manufacturing, Inc. for technical support. 1.26. DO NOT MODIFY VESSEL. Do Not modify or alter any abrasive blaster, blast equipment, or controls thereof without written consent from Axxiom Manufacturing, Inc.
Page 13 1.33. ALWAYS USE REMOTE CONTROLS. Do Not sell, rent, or operate abrasive blasters without remote controls. OSHA regulations require remote controls on all abrasive blasters. All abrasive blasters must be equipped with automatic (deadman) type remote controls (either pneumatic or electric). Failure to use remote controls can cause serious injury or death to the operator(s) or other personnel in the blasting area.
Page 14 1.39. NEVER AIM BLAST NOZZLE TOWARDS ANY PERSON. Do Not aim the blast nozzle towards yourself or any person. System malfunction can cause accidental start up and result in injury to personnel. 1.40. NEVER USE ABRASIVE NOT INTENDED FOR BLAST EQUIPMENT. Do Not use abrasive blast media containing free silica.
Page 15: Specifications And General Information
Specifications and General Information Notes to Distributors and Owners 2.1.1. Verify that the deadman, twinline (or cords), and the operation and maintenance manual are included with the abrasive blaster when it is received. Verify that the deadman, twinline (or cords), and the operation and maintenance manual are included with the abrasive blaster when it is delivered to the purchaser.
Page 16 Vessel Information 2.4.1. All pressure vessels used in Schmidt® Abrasive Blasters are manufactured in strict accordance with the provisions of the ASME Code Section VIII, Div. 1. 2.4.2. In order to maintain the high level of quality and quality control used in the manufacture of this vessel, it is required that any and all welded repairs to this vessel be performed by a reputable shop holding a National Board “R”...
Page 18: Installation Requirements And Personal Protective Equipment
Installation Requirements and Personnel Protective Equipment Carefully read and follow all the recommendations regarding the abrasive blast system installation requirements. Improper installation can result in equipment malfunction and significant lost time expenses. Consult an authorized Schmidt® distributor or Axxiom Manufacturing, Inc. Abrasive Blast System Installation Location i.
Page 19 Blast System Air Supply Line The air supply hose and fittings must be rated at a minimum of 150 psi operating pressure. The air supply hose from the air compressor to the blast unit should be at least the same diameter as the air inlet piping (see Section 9.0).
Page 20 Abrasive Selection Abrasive selection is likely the most difficult decision related to the blast operation. Choice of abrasive is based on factors such as blast application type, desired finish and coating requirements, characteristics of object to be blasted, cost and ability to recycle, available equipment, safety, and environmental constraints.
Page 21 3.10 Personal Protective Equipment (PPE) Abrasive blasting has many hazards that may cause injuries to operators. To protect operators from injury each must be supplied with, and required to use Personal Protective Equipment. The Occupational Health and Safety Administration (OSHA) requires the employer to assess the workplace to determine what PPE is necessary and supplied to each operator (Reference 29 CFR 1910 Subpart I).
Page 22 3.11 Pressure Relief Valve Installation Do Not operate this equipment without a pressure relief device installed to protect the blaster pressure vessel from over-pressurization. The ASME Code requires that all vessels be operated with pressure relief devices in place. If the compressed air system does not provide for the installation of a pressure relief valve one can be installed on the blowdown port on the pressure vessel.
Page 23 3.12 INSTALLATION CHECKLIST (Photocopy this page to use as an installation worksheet.) □ Deadman/Twinline (or cords): confirm delivery with the abrasive blaster. □ Blast accessories: confirm receipt as purchased with the blaster. □ Inspect blaster: check for possible damage during shipment. See Section 8.0 for inspection instructions.
Page 24: Abrasive Blast System General Operation
Abrasive Blast System General Operation The function of the Schmidt® abrasive blaster is to provide a mixture of dry abrasive and compressed air to a blast nozzle. The abrasive blast stream through the blast nozzle is used for removing rust, paint, or other unwanted surface defects.
Page 25: Mini Blast System General Operation
Mini Abrasive Blaster General Operation See Figure 5.1 below to help understand the general operation of a Mini abrasive blaster. Do not attempt to operate the Mini abrasive blaster before reading all sections of this manual and following all setup procedures. Read sections 5.1 through 5.11 for a detailed explanation of all components of the Mini abrasive blaster.
Page 26 Popup with Eyebolt (abrasive inlet) The blaster is filled with abrasive through the abrasive inlet at the top of the pressure vessel. This opening is sealed by the popup head (#5) when it is pulled up against the gasket (#6) and the blaster is pressurized.
Page 27 Blowdown Ball Valve (depressurize) The blowdown ball valve (#4) is used to release all the compressed air (depressurize) from inside the abrasive blaster. The abrasive blaster must be depressurized before filling with abrasive or before performing any maintenance. The air inlet ball valve (#3) must be closed before depressurizing the abrasive blaster.
Page 28 Thompson Valve® II (abrasive metering valve) The Thompson Valve (#14) is a normally closed valve that opens to supply abrasive into the blast air stream. The Thompson Valve opens when it receives air to its signal port (see Section 9.2(a) and 9.2(b)). This happens when the deadman lever (#12) is pressed down which sends an air signal to the Thompson Valve.
Page 29 Deadman Valve/Switch (blast control) The deadman valve/switch is part of a system that controls the blast operation. The deadman valve/switch (#12) allows the operator to remotely start and stop the blast operation. The deadman is mounted at the end of the blast hose assembly (#10) close to the blast nozzle (#11) to give the operator easy control of the blast operation.
Page 30 Note: To reduce operator fatigue a blast whip hose can be used along with the blast hose. A whip hose is thinner wall and lighter weight hose. Consult an Authorized Schmidt® distributor. 5.10 Blast Nozzle The blast nozzle (#11) is an important part of the blast operation since the size of it determines the air flow and abrasive requirement.
Page 31: Pre-Operation Procedures
Pre-operation Procedures Failure to follow the procedures below could result in serious injury or death. In addition to these procedures completely read and understand all sections of this Abrasive Blaster Operation and Maintenance Manual. The Abrasive Blaster is a pressurized vessel. Propelled objects will cause serious injury or death. Depressurize vessel before performing any maintenance.
Page 32 6.1.6. Wire tie the twinline hose (#15) or electric deadman extension cords to the blast hose assembly (#10). 6.1.7. Screw nozzle (#11) into the nozzle holder (#25) at end of the blast hose assembly (#10). 6.1.8. Connect the blast hose coupling (#26) to the threaded coupling (#27) on the abrasive metering valve (#14).
Page 33 Mini Abrasive Blaster Depressurizing Procedure (Blowdown) Do not leave the abrasive blaster pressurized during long periods of no usage. Undetected air leaks can cause costly wear damage to the pressure vessel (i.e. at abrasive inlet and handways). 6.2.1. Mini Abrasive Blast System (See Figure 6.2) A Mini abrasive blaster is a pressurized system;...
Page 34: Operating Instructions
Operating Instructions Filling the Abrasive Blaster with Abrasive 7.1.1. The Mini Abrasive blaster must be completely depressurized before filling with abrasive. Follow the depressurizing procedure in Section 6.2. Disable the blaster by closing the air inlet ball valve (#3). Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing.
Page 35 Beginning the Blasting Operation (See Figure 7.2) 7.2.1. The Mini Abrasive Blaster must be properly setup and all operating personnel must be thoroughly trained before beginning the blast operation. All operators must completely read and understand all sections of this manual before beginning the blast operation. See the pre-operation setup procedures given in Section 6.0.
Page 36 7.2.11. Observe the blast stream and the coating removal rate. A bluish color in the blast stream indicates a good abrasive to air mixture. Release the deadman lever to stop blasting. 7.2.12. If necessary adjust the abrasive flow with the knob on the Thompson Valve® (#14). Turn clockwise for less abrasive flow, or turn counter-clockwise for more abrasive.
Page 37 Ending the Blast Operation (See Figure 7.3) Do not leave the abrasive blaster pressurized during long periods of no usage. Undetected air leaks can cause costly wear damage to the pressure vessel (i.e. at abrasive inlet and handways). 7.3.1. Close the air inlet ball valve (#3). The ball valve is closed when the handle is fully turned to the position shown in Figure 7.3 (handle perpendicular to body).
Page 38: Maintenance And Inspection Instructions
Maintenance and Inspection Instructions The abrasive blaster is a Pressurized Vessel. Propelled objects will cause serious injury or death. Depressurize vessel before performing any maintenance. See Section 6.2. For proper operation, maintenance should be performed with the assistance of a qualified serviceman. 8.1.
Page 39 Figure 8.1 – Standard Popup Assembly and Internal Piping 8.6. Blast and Air Hoses: All air hoses, blast hoses, control hoses, and wires should be inspected daily for wear, dry rotting, cracking or leakage. Repair or replace any hoses or wires that show any signs of wear, leakage or other damage.
Page 40 8.8. Blast and Air Hoses: All air hose, blast hose, and threaded couplings have gaskets that seal the connection. To reduce loss of air pressure and/or premature abrasive wear replace these gaskets when leaks are found. Inspect the couplings daily for leaks and wear. Replace gaskets when visible wear or leaks are found.
Page 41 8.15. Maintenance Schedule Quick Reference Chart SMALL POT ABRASIVE BLASTER MAINTENANCE SCHEDULE MAINTENANCE ITEM DAILY WEEKLY MONTHLY QUARTERLY REQUIRED Blaster Hydrostatic Test As required by state law and/or local authorities Vessel See Section 8.1 Check for exterior damage Blaster (corrosion, dents, bulges). Vessel See Section 8.2 Check for interior damage...
Page 43: Drawings And Parts Lists
Drawings and Parts Lists The following pages contain drawings representing typical blast control systems and components. Determine the type of control system the abrasive blast system is equipped with (pneumatic or electric controls) then reference the appropriate drawing and parts list to determine the required parts.
Page 51: Recommended Spare Parts Lists
10.0 Recommended Spare Replacement Parts Lists Mini Abrasive Blaster Recommended Spare Parts [see Section 9.1(a)] Item No. Qty. Part No. Description 2123-006-02 Auto Air Valve Diaphragm, 3/4" 2123-006-99 Auto Air Valve Replacement Part Kit, 3/4" 2123-105 Auto Air Valve, 3/4" 2123-106-24 Auto Air Valve Spring, 3/4"...
Page 52: Troubleshooting
11.0 Troubleshooting This section lists probable causes of problems that may occur during operation of the abrasive blaster. Not all of the “probable causes” may apply to your particular abrasive blaster. The probable cause may not apply because of the control type and accessories on the abrasive blaster. Refer to Figure 11.1 and the drawings in Section 9.0.
Page 53 Figure 11.1 – Mini Abrasive Blaster with pneumatic blast controls 11.2 Malfunction With Deadman Lever In The “On” Position 11.2.1. Air blasts with no abrasive (1) Check abrasive level in blast vessel (even if optional second outlet blasts normally). (2) Blocked control air hose to Thompson Valve® (#14) prevents opening. (3) Thompson Valve (#14) plunger stuck in closed position.
Page 54 11.2.4. Blast is slow to turn on or will not turn on when deadman lever is pressed down. (1) Check quick couplings (#16 & #17) on control hoses to see if they are connected properly. (2) Control valve (#20) stuck in exhaust position or midway (air will leak from breather #21). (3) 1/4"...
Page 55: Warranty And Reference Information
12.0 Warranty and Reference Information 12.1 Warranty This following section is to be used as a guide in determining warranty policies and procedures products. It is to be used in determining whether a warranty is justified and as a SCHMIDT® procedural guide in completing a warranty claim.
Page 56 9. Axxiom Manufacturing, Inc. reserves the right to make product changes or improvements without prior notice and without imposing any obligation upon itself to install the same on its products previously sold. 10. The above warranty conditions can only be altered by Axxiom Manufacturing, Inc. Axxiom must confirm alterations in writing for each specific transaction.
Page 57 12.4 Safety Information Sources Axxiom Manufacturing, Inc This equipment and all Schmidt® equipment are manufactured exclusively by Axxiom Manufacturing, Inc. If any operational or safety related questions arise relating to this equipment contact Axxiom Manufacturing, Inc. Phone: 1-800-231-2085 Website: www.schmidtabrasiveblasting.com Axxiom Manufacturing, Inc.
Page 58 12.5 Surface Preparation Information Sources The Society for Protective Coatings (SSPC) consists of research and testing committees, conducts seminars and establishes industry standards on surface preparation methods, abrasive and coatings. Phone: 1-412-281-2331 Website: www.sspc.org The Society for Protective Coatings 40 24th Street Pittsburg, PA 15222-4643 National Association of Corrosion Engineers (NACE) develops test methods and recommended practices on surface preparation techniques and coatings.
Page 60: Blasting Data Tables
13.0 Blasting Data 13.1 Table 1 Approximate Air Consumption (CFM) Per Blast Nozzle NOZZLE PRESSURE NOZZLE SIZE 60 psi 70 psi 80 psi 90 psi 100 psi 120 psi 140 psi No.2 1/8" No.3 3/16" No.4 1/4" No.5 5/16" No.6 3/8"...

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