AXXIOM Manufacturing, Inc. SCHMIDT 120 Operation And Maintenance Manual

Bulk abrasive blaster

Hide thumbs

Table Of Contents

Quick Links

Download this manual

BULK ABRASIVE BLASTER

OPERATION AND MAINTENANCE MANUAL

JULY 2010

SAVE THIS MANUAL AND MAKE AVAILABLE

TO ALL USERS OF THIS EQUIPMENT!

Manual Part Number 7200-205

IOM Manufacturing, Inc.

11927 S. Highway 6, Fresno, Texas 77545

800.231.2085 * 281.431.0581 * fax 281.431.1717

Table of Contents

Need help?

Do you have a question about the SCHMIDT 120 and is the answer not in the manual?

Questions and answers

Summary of Contents for AXXIOM Manufacturing, Inc. SCHMIDT 120

Page 1 BULK ABRASIVE BLASTER OPERATION AND MAINTENANCE MANUAL JULY 2010 SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL USERS OF THIS EQUIPMENT! Manual Part Number 7200-205 © 2010 A IOM Manufacturing, Inc. 11927 S. Highway 6, Fresno, Texas 77545 800.231.2085 * 281.431.0581 * fax 281.431.1717...
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 0.1a and 0.1b for images of the warning decals. Refer to Figure 0.2 for the locations of these warning decals on the bulk abrasive blaster.
Page 5 4) 7031-012A 5) 7031-070 6) 7034-001 7) 7031-057 8) 7031-009A (Trailer mounted units only) Figure 0.1b –Warning decal summary continued © 2010 Axxiom Manufacturing, Inc.
Page 7: Table Of Contents
Table of Contents Section Page Warning Decal Identification and Location Rules for Safer Operation Specifications and General Information System Requirements and Personal Protective Equipment Abrasive Blast System General Operation Abrasive Blaster 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. THE SCHMIDT® BULK ABRASIVE BLASTER HAS BEEN DESIGNED TO BE SAFE WHEN USED IN THE PROPER MANNER. ALL ABRASIVE BLASTERS ARE POTENTIALLY DANGEROUS SAFETY PRECAUTIONS 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 generated by the blast nozzle and the blowdown operation of this equipment. Wear OSHA approved hearing protection.
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 1.34. DEPRESSURIZE VESSEL BEFORE PERFORMING MAINTENANCE. Do Not remove, repair, or replace any item on this equipment while it is pressurized. Do Not attempt to perform maintenance or load abrasive while this equipment is pressurized or is even capable of being pressurized. This means the inlet ball valve should be closed and the air supply should be shut off or disconnected.
Page 14 1.40. ALWAYS USE CORRECT PRESSURE RATED ACCESSORIES. Do Not use air reservoirs or moisture separator tanks that are not rated for use in compressed air applications. Air reservoirs and moisture separator tanks larger than 6 inches inside diameter must have an ASME code stamp. An air reservoir or moisture separator tank is a Pressurized Vessel.
Page 15 1.49. DO NOT SIDE LOAD BULK ABRASIVE BLASTER TRAILER. Do Not exert side loads on the trailer wheels. An example of side loading would be pushing the trailer mounted bulk abrasive blaster on its side with a fork lift or other similar heavy equipment.
Page 16: Specifications And General Information
Specifications and General Information Notes To Distributors and Owners 2.1.1. Remove the manway cover and verify that the deadman, twinlines (or cords), and the operation and maintenance manual are inside the blaster vessel when it is received. Verify that the deadman, twinlines (or cords), and the operation and maintenance manual are inside the blaster vessel when it is delivered to the purchaser.
Page 17 Important Reference Numbers Fill in the Bulk Abrasive Blaster model number and serial number in the blank spaces below. These will be used for reference whenever service or maintenance is required. Bulk Abrasive Blaster Model Number Bulk Abrasive Blaster Serial Number Vessel Information 2.4.1.
Page 18 Bulk Abrasive Blaster Lifting Diagrams An abrasive blaster is a Pressurized Vessel. The compressed air inside a pressurized vessel contains a dangerously high level of energy which can propel objects and cause serious injury or death. Depressurize vessel before lifting, moving, or transporting. ©...
Page 20: System Requirements And Personal Protective Equipment
System Requirements and Personal 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 21 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 22 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 23 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 24 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 25: 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 26: Abrasive Blaster General Operation
Abrasive Blaster General Operation See Figure 5.1 below to help understand the general operation. Do not attempt to operate the bulk abrasive blaster before reading all sections of this manual and following all setup procedures. See Sections 5.1 through 5.14 and Section 6.0. The Bulk Abrasive Blaster (#4 &...
Page 27 Closure (abrasive inlet) The blaster is filled with abrasive through the closure abrasive inlet at the top of the pressure vessel. The closure is a manually operated 10” hinged opening that is opened only when the blast vessel is depressurized. Refer to Section 6.2 for depressurization procedure. The closure is opened and closed by following the procedures detailed in Sections 6.3 and 6.4.
Page 28 Choke Valve The choke valve (#9) is a ball valve located in the blast air line upstream of the Thompson Valve®. The choke valve (#9) is used to clear any trash that may get into the blast vessel and block the Thompson Valve orifice. Whenever trash (paint chip, cigarette butt, etc.) blocks the Thompson Valve orifice the procedure is to fully open the Thompson Valve knob, then press down the deadman lever (#1) to begin blasting.
Page 29 Thompson Valve® II (abrasive metering valve) The Thompson Valve (#13) is a dual-purpose valve. First, it 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 9.4 and 9.5). This happens when the deadman lever (#1) is pressed down which opens the blast control valve (#12) sending an air signal to the Thompson Valve.
Page 30 Figure 5.2 – Union End Ball Valve 5.10 Deadman Valve/Switch The Deadman valve/switch is part of a system that controls the blast operation. The deadman valve/switch (#1) allows the operator to remotely start and stop the blast operation. The Deadman is mounted at the end of the blast hose assembly (#19) close to the blast nozzle (#21) to give the operator easy control of the blast operation.
Page 31 5.10.2. Electric Deadman System: When the electric deadman lever is pressed down it closes the electric circuit and supplies electric current to the control valve (#12). The control valve opens and sends air signals to the auto air valve (#10) and the Thompson Valve® (#13). When the deadman lever is released the electric circuit is cut off closing the control valve.
Page 32 5.13 Blast Nozzle The blast nozzle (#21) is an important part of the blast operation since the size of it determines the air flow and abrasive requirement. The amount of air flow and abrasive determine how quick blasting can be done. The larger the nozzle, the more the air and abrasive will be needed. The larger the nozzle size the greater the blast productivity.
Page 33: 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 Bulk Abrasive Blaster Operation and Maintenance Manual. The closure is part of a Pressurized Vessel. Propelled objects will cause serious injury or death. Depressurize vessel before opening closure.
Page 34 6.1.8. Verify that all required personal protective equipment is available for each operator and in good operating condition (safety glasses, safety shoes, ear plugs, gloves, airline filter, respirator, & carbon monoxide monitor). Critical: Adhere to all local, state, and federal regulations including, but not limited to, OSHA (Occupational Health and Safety Administration).
Page 35 6.1.14. The following steps only apply to abrasive blasters with electric blast control systems. 6.1.15. Connect the electric power cord (#41) to the blaster junction box connector (#43). 6.1.16. Connect the electric power cord alligator clips (#40) to the air compressor battery terminals or to another 12Vdc power source.
Page 36 Bulk Abrasive Blaster Depressurizing Procedure (Blowdown) 6.2.1. Close the air inlet ball valve (#7). The ball valve is closed when the handle is fully turned to the position shown in Figure 6.2 (handle perpendicular to body). The handle tab will bottom against the ball valve body in the closed position. 6.2.2.
Page 37 Closure Opening Procedure (See Figure 6.2 and 6.3) The closure is part of a Pressurized Vessel. Propelled objects will cause serious injury or death. Depressurize vessel before opening closure. See Section 6.2. 6.3.1. Taking the proper fall protection measures, access the closure (#5) using the bulk abrasive blaster ladder.
Page 38 DO NOT swing any of the swing bolts (#14) out of the holding lugs at this time. Swinging any swing bolts at this time will disable the safety feature of the closure. When all the camlock handles are in the open position the closure head can move up slightly.
Page 39 6.3.7. Each time the closure is opened all the camlock assemblies and hinge assemblies must be inspected for damage, including but not limited to, corrosion, cracks, and deformations. Make sure all the swing bolts, nuts, washers, cams, spring pins, and handles are in place (See Drawing 9.3(a)).
Page 40 Closure Closing Procedure (See Figure 6.3) 6.4.1. Inspect the closure head and sealing surface for damage including, but not limited to, corrosion, cracks, or deformations. Check that the 10” o-ring is fitted in the groove at the bottom of the closure head. Remove and inspect the closure o-ring for cuts or tears. Replace if necessary.
Page 41 Figure 6.3 – Bulk Abrasive Blaster Closure Assembly 6.5.5. After all the swing bolts are in position within the holding lugs rotate the Halok (#25) clockwise to allow access to the camlock handles (#14). See Figure 6.3. 6.4.6. In the numbered sequence shown in Figure 6.3(b), tighten each swing bolt by swinging each of the five camlock handles into the “closed position”...
Page 42 Manway Cover Installation Procedure (See Figure 6.5(a)) 6.5.1. Check that the manway cover, crabs, bolts, and gasket are dimensionally correct for the size manway weld ring of the pressure vessel. a) Measure and write down the inside dimensions “A” and “B” of the manway weld ring.
Page 43 Figure 6.5 (a) – Manway Assembly Figure 6.5 (b) – Manway Components Manway Dimensions 11” x 15” 12” x 16” Component Weld Ring 11-3/8” 15-1/4” 12-1/2” 16-3/8” Manway Cover 14-1/8” 17-5/8” 14-3/4” 18-3/8” Manway Gasket 14” 17-3/4” 14-3/4” 18-3/8” Manway Crab 2”...
Page 44: Operating Instructions
Operating Instructions Filling The Bulk Blaster With Abrasive 7.1.1. The bulk abrasive blaster must be completely depressurized before filling can begin. Follow the depressurizing procedure in Section 6.2. Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing.
Page 45 Beginning the Blasting Operation (See Figure 7.3) 7.2.1. The bulk abrasive blaster must be properly prepared and all operating personnel must be thoroughly trained before beginning the blast operation. Completely read and understand all sections of this manual before beginning the blast operation. See the pre- operation procedures given in Section 6.0.
Page 46 Ending the Blast Operation (See Figure 7.3) 7.3.1. Close the air inlet ball valve (#7). The ball valve is closed when the handle is fully turned to the position shown in Figure 7.3 (handle perpendicular to body). The handle tab will bottom against the ball valve body in the closed position. Do not turn off the air compressor and allow the abrasive blaster air pressure to back flow through the system.
Page 47: Maintenance And Inspection Instructions
Maintenance and Inspection Instructions The bulk 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 48 8.5. Closure Assembly: After any camlock assembly is disassembled or replaced the nut torque must be reset per the procedure described below. Check the camlock assembly nut torque weekly thereafter. CAMLOCK ASSEMBLY ADJUSTMENT PROCUDURE a) Inspect all closure components per Section 8.4 b) Remove the upper camlock assembly lock nuts.
Page 49 8.8. Blast/Air Hose Coupling Gaskets: All air hose, blast hose, and threaded couplings have gaskets that seal the connection. To prevent 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 50 8.13. Vessel Manway Assembly: Check weekly for air leaks around the manway assembly. Confirm correct assembly components. Refer to Section 6.5 for installation and inspection procedures. 8.14. Moisture Separator: The moisture separator should be cleaned quarterly to improve air flow. Pressure wash downward through the top head coupling.
Page 51 8.16. Vessel Mount Bolts: Check the vessel to trailer mounting bolt torque upon delivery of the new bulk abrasive blaster. Re-torque the mounting bolts after the first 50 miles of use. Check the mounting bolt torque quarterly thereafter. Torque the vessel to trailer mounting bolts to 98 ft lb. See the drawing in Section 9.3(a).
Page 53: 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 70: Recommended Spare Parts Lists
10.0 Recommended Spare Parts Lists Annual Recommended Spare Parts For A Bulk Abrasive Blaster (4-outlet) A) ELECTRIC and PNEUMATIC CONTROLS (see note below) PART # DESCRIPTION 2123-00X-02 Auto Air Valve Diaphragm (specify size) 2123-00X-99 Auto Air Valve Replacement Parts Kit (specify size) 2123-10X Auto Air Valve (specify size) (See Section 9.7) 2123-10X-24...
Page 71: 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 each 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 72 Figure 11.1 – Typical Bulk Abrasive Blaster 11.2 Malfunction With Deadman Lever In The “On” Position 11.2.1. Air blasts with no abrasive (1) Check abrasive level in the blast vessel even if one outlet continues to blast normally. (2) Blocked control hose to Thompson Valve® (#13). (3) Thompson Valve plunger stuck in closed position.
Page 73 11.2.4. Blast is slow to turn on or will not turn on when deadman lever is pressed down. (1) Check quick couplings (#17) on control hoses to see if they are connected properly. (2) Control valve (#12) stuck in exhaust position. (3) 1/4"...
Page 74 11.4 Troubleshooting Trailer Hydraulic Brakes 11.4.1. Dragging Brakes (1) Check brake adjustment. (2) Check for faulty master cylinder. (3) Check for improperly installed backing plate. (4) Check for corroded brake assembly. (5) Improper weight on trailer tongue. 11.4.2. Noisy Brakes (1) Check brake adjustment.
Page 75 11.4.7. Swaying of Trailer When Braking (1) Incorrect brake adjustment. (2) Incorrect tire air pressure. (3) Different tire sizes on axle. (4) Shoe or lining not properly operating. (5) Brake lines damaged 11.4.8. Brake Adjustment Procedure (1) Jack up trailer and support with jack stands. (2) The brake adjustment nut is located behind a slot at the bottom of the backing plate.
Page 76 11.5 Troubleshooting Trailer Electric Brake 11.5.1. Dragging Brakes (1) Check brake adjustment. (2) Check for defective controller. (3) Check for improperly installed backing plate. (4) Check for corroded brake assembly. (5) Check for weak or broken brake shoe return spring. (6) Check for worn or damaged lever arm between magnet and brake shoe.
Page 77 11.5.8. No Brakes (1) Check for defective circuit breakers. (2) Check for open or shorted circuit. (3) Check for properly wired system, including ground between towing vehicle and trailer. (4) Check for defective controller or loose wiring at controller. (5) Check brake adjustment. (6) Check for defective resistor or loose wiring at resistor.
Page 78: 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 79 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 80 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.axxiommfg.com Axxiom Manufacturing, Inc.
Page 81 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 82 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"...

This manual is also suitable for:

Schmidt 160