Schmidt AmphiBlast 120 Operation And Maintenance Manual

Abrasive blaster

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Bulk AmphiBlast™ 120/160CF

OPERATION AND MAINTENANCE MANUAL

May 2019

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Manual Part Number 7200-335-01

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IOM Manufacturing, Inc.

11927 S. Highway 6, Fresno, Texas 77545

800.231.2085 * 281.431.0581 * fax 281.431.1717

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Page 1 Bulk AmphiBlast™ 120/160CF OPERATION AND MAINTENANCE MANUAL May 2019 SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL USERS OF THIS EQUIPMENT! Manual Part Number 7200-335-01 (Available for downloading from SchmidtAbrasiveBlasting.com) Copyright © 2019 A IOM Manufacturing, Inc. 11927 S. Highway 6, Fresno, Texas 77545 800.231.2085 * 281.431.0581 * fax 281.431.1717 Website Visit us at www.SchmidtAbrasiveBlasting.com...
Page 2 8. Do Not modify or alter any abrasive blaster, blast equipment or controls thereof without written consent from Axxiom Manufacturing, Inc. 9. Do Not use bleeder type deadman valves on any Schmidt® abrasive blaster. The use of A-BEC, Clemco or a similar bleeder type deadman valve can cause unintentional start-up without warning, which can result in serious personal injury.
Page 3 Manual Use, Explanation of Safety Symbols, and Glossary This manual contains information needed to operate and maintain a Schmidt® AmphiBlast™. Read this entire operations and maintenance manual before using the AmphiBlast. Pay close attention to the Rules for Safer Operation (Section 1.0), and the Dangers, Warnings, and Cautions identified.
Page 4: Warning Decal Identification And Location
Figure 0.1(a) thru 0.1(c) for images of the warning decals. Refer to Figures 0.2(a) and 0.2(b) for the locations of these warning decals on the abrasive blaster. Qty. Part no. Description Hazard X-Large “Schmidt” 7031-000 Not Applicable Airborne particles and loud noise from blast “Warning” nozzle and blowdown can cause injury and...
Page 5 3) 7031-007A 4) 7031-057 5) 7031-090 6) 7031-082 7) 7034-001 (welded) 7) 7031-084 (decal) (Units manufactured after September 2017) Figure 0.1(b) – Warning Decal Summary (continued) Copyright © 2019 Axxiom Manufacturing, Inc.
Page 8: 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 AmphiBlast™ System General Operation Pre-operation Procedures Operating Instructions Maintenance and Inspection Instructions Drawings and Parts Lists 10.0 Recommended Spare Parts Lists...
Page 9: Rules For Safer Operation
Do Not operate this equipment in a manner other than its intended application (see Section 4.0). Do Not operate this equipment or any other Schmidt® equipment without following the Rules for Safer Operation and all the operating procedures and instructions. Learn the applications and limitations as well as the specific potential hazards related to this machine.
Page 10 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 11 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 12 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 13 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 14 Reference OSHA 29 CFR 1910.244(b). 1.36. NEVER USE BLEEDER TYPE DEADMAN VALVES. Do Not use bleeder type deadman valves on any Schmidt® abrasive blaster. The use of A-BEC, Clemco, or a similar bleeder type deadman valve can, without warning, cause unintentional start-up which can result in serious personal injury.
Page 15 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 16 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 17: Specifications And General Information
See the lifting diagrams shown in Section 2.6. 2.1.6. For further information on options and accessories available for Schmidt® abrasive blasters visit the Axxiom website or contact us: Axxiom Manufacturing, Inc.
Page 18 Important Reference Numbers Fill in the Abrasive Blaster model number, serial number, and other information in the blank spaces below. This information will be needed for reference when service, maintenance, or technical support is required. Blaster Model Number Blaster Serial Number National Board Number Blaster Piping Size______________ Vessel Information...
Page 19 2.6(a) Bulk AmphiBlast™ Lifting Diagram and Dimensional Specifications 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. See Section 6.2 Copyright ©...
Page 22: Installation 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 23 (i.e. coalescing moisture separator, air-cooled aftercooler or deliquescent dryer). Contact a local authorized Schmidt® distributor or Axxiom Manufacturing, Inc. to locate one near you.
Page 24 Use these sources to obtain information regarding all aspects of surface preparation and abrasive selection guidelines. Schmidt® abrasive blasters are designed for high production open abrasive blasting with a wide range of abrasives. It is the responsibility of the employer and operators to select the proper abrasive.
Page 25 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 26 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 vessel piping by removing the 1-1/2”...
Page 27 3.12 INSTALLATION CHECKLIST ( Photocopy this page to use as a worksheet) □ Deadman/Twinline (or cords): confirm delivery with the abrasive blaster. □ Manway covers & crab assemblies: confirm delivery with the abrasive blaster. □ Blast accessories: confirm receipt as purchased with the blaster. □...
Page 28: Abrasive Blast System General Operation
Since moisture creates problems in the blast operation, it is common for the compressed air to be fed through a moisture removal device, such as a Schmidt AirPrep System. The air pressure in the abrasive blast vessel is equal to the air pressure in the blast hose where it connects at the metering valve.
Page 29: Amphiblast™ System General Operation
Bulk AmphiBlast™ General Operation See Figure 5.1 to help understand the general operation of the Bulk AmphiBlast™. Do not attempt to operate the Bulk AmphiBlast before reading all sections of this manual and following all setup procedures. Read Sections 5.1 through 6.0. The Bulk AmphiBlast is a pressurized system;...
Page 31 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 32 Choke Valve The choke valve (#13) is used to clear any trash that may get into the blast vessel and block the Thompson® Valve orifice. Whenever trash (paint chips, cigarette butts, etc.) blocks the Thompson Valve orifice the procedure is to fully open the Thompson Valve by backing out the knob, then press down the deadman lever (#12) to begin blasting.
Page 33 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 34 (#27) and the blast hose assembly (#10). 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. 5.13 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 35 Figure 5.4 – Hose Connection Disconnect Protection 5.15 Abrasive Shut-Off Valve The abrasive shut-off valve (#54) is used to block the abrasive flow to the Thompson® Valve (#14). This allows the user to remove the Thompson Valve from the blast vessel without emptying the abrasive.
Page 36 5.17 Blast Pressure Regulator To blast objects that are fragile it is necessary to reduce the blast air pressure. The blast pressure regulator (#44) is used to adjust the blast pressure while in “BLAST MODE”. The blast pressure is shown by the blast pressure gauge (#49). The adjustment must be made while blasting so the effects are visible.
Page 37 (#27) and the blast hose assembly (#10). 5.25 Multiple Outlet Blast System The AmphiBlast™ can be purchased with up to 4-outlets. Consult Axxiom Manufacturing or an Authorized Schmidt® distributor. Each blast outlet of multiple outlet blast vessels operate as detailed in the sections of this manual.
Page 38: 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 AmphiBlast Operation and Maintenance Manual. The closure assembly is part of a pressurized vessel. Propelled objects will cause serious injury or death.
Page 39 6.1.7. Hose clamp the deadman (#12) to the blast hose assembly (#10) in a comfortable position behind the nozzle holder (#25). 6.1.8. Wire tie the twinline hose (#15) or electric deadman extension cords to the blast hose assembly (#10). 6.1.9. Screw nozzle (#11) into the nozzle holder (#25) at end of the blast hose assembly (#10). 6.1.10.
Page 40 #7). The exhaust air flow is controlled and muffled by the CEN system (#26). The CEN Exhaust System minimizes freezing at the blowdown and reduces noise level. Note: The CEN System is standard on Schmidt® bulk blasters manufactured after February 2010. Airborne particles and loud noise hazards from blowdown exhaust air can cause serious injury and loss of hearing.
Page 41 Closure Assembly Opening Procedure (See Figure 6.2, 6.3.1 and 6.3.2) The closure assembly is part of a Pressurized Vessel. Propelled objects will cause serious injury or death. Depressurize vessel before opening the closure assembly. See Section 6.2. 6.3.1. Taking the proper fall protection measures, access the closure (#5) using the bulk abrasive blaster ladder.
Page 42 DO NOT swing any of the swing bolts out of the holding lugs at this time. Swinging any swing bolts at this time will disable the safety feature of the closure assembly. When all the camlock handles are in the open position the closure head can move up slightly.
Page 43 6.3.7. Each time the closure assembly 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)). Inspect the threads of each swing bolt and (2) nuts for corrosion or wear.
Page 44 Closure Assembly Closing Procedure (See Figure 6.4.1 and 6.4.2) 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 45 Figure 6.4.1 – Bulk Abrasive Blaster Closure Assembly 6.4.6. In the numbered sequence shown in Figure 6.4.1(b), tighten each swing bolt by swinging each of the five camlock handles into the “closed position” against the closure head. If necessary a 1/2” pipe 12 inches long can be slipped over the end of the camlock handle to increase leverage.
Page 46 Manway Cover Installation Procedures (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 47 Figure 6.5 (a) – Manway Assembly Figure 6.5 (b) – Manway Components Manway Component Dimensions *11” x 15” **12” x 16” ***14” x 18” Component Weld Ring 11-3/8” 15-3/8” 12-1/2” 16-3/8” 13-7/8” 17-7/8” Manway Cover 14-1/8” 17-5/8” 14-3/4” 18-3/8” 16-3/4” 20-3/8”...
Page 48: Operating Instructions
7.1.3. Fill the bulk abrasive blaster as needed. To fill from a Schmidt® storage hopper, pull the bulk abrasive blaster below it lining up the closure under the slide valve outlet. Open the slide valve and fill the bulk blaster as needed.
Page 49 Filling the Water Tank (Not Included) 7.2.1. Close water tank drain/pressure washer connection port ball valve. 7.2.2. Unscrew water tank cap and set to side. 7.2.3. Fill water tank with fresh clean water to the desired level. 7.2.4. If required, rust inhibitor can be added to the water tank. Follow the instructions from the rust inhibitor manufacturer for the correct amount.
Page 50 7.4.3. Open the choke valve (#13). 7.4.4. Switch the mode selector (#47) to “BLAST MODE”. 7.4.5. Turn the water off by pushing in the palm button on the water on/off palm button control valve (#48) 7.4.6. Turn the abrasive cutoff valve/switch (#62) to the “OFF” position. See Figure 5.3. 7.4.7.
Page 52 Beginning the Dry Blasting Operation 7.5.1. The 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 procedures given in Section 6.0.
Page 53 7.5.14. With one hand grip the blast hose assembly (#10) and with the other hand press in the deadman safety button. To begin blasting, aim the blast nozzle at the object to be blasted, then firmly press down the deadman lever (#12). Air and blast abrasive will flow into the blast hose and out of the blast nozzle (#11).
Page 54 7.6.7. Turn the abrasive cutoff valve/switch (#62) to the “OFF” position. See Figure 5.3. 7.6.8. For initial startup the Thompson® Valve (#14) should only be partially open. Turn the valve knob clockwise to completely close, then turn counterclockwise about four turns to partially open.
Page 55 7.6.19. With one hand grip the blast hose assembly (#10) and with the other hand press in the deadman safety button. To begin blasting, aim the blast nozzle (#11) at the object to be blasted, then firmly press down the deadman lever (#12). Air and wet blast abrasive will flow into the blast hose and out of the blast nozzle (#11).
Page 56 Blow Off Operation 7.8.1. Switch the mode selector (#47) to “BLAST MODE”. 7.8.2. Turn the water “Off” by pushing in the palm button on the water on/off palm button control valve (#48) 7.8.3. Turn the abrasive cutoff valve or switch (#62) to the “OFF” position. See Figure 5.3. 7.8.4.
Page 57: Maintenance And Inspection Instructions
Maintenance and Inspection Instructions The Bulk AmphiBlast™ 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 58 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 59 Depressurize vessel before performing any maintenance. See Section 6.2. Removing the Thompson valve bolts with the abrasive blaster pressurized will result in serious injury or death. Use of replacement components that are not Schmidt® original factory replacement parts may result in equipment failure which can result in serious personal injury.
Page 61 8.11. Blowdown Ball Valve: The blowdown ball valve (#4) is used to depressurize the abrasive blaster pressure vessel (#1). See Figure 8.4. The blowdown air flow can carry abrasive from inside the pressure vessel which can wear the blowdown ball valve (#4) and piping. This wear will cause the blowdown ball valve (#4) to be difficult to open and/or close, and/or result in the inability to close properly (air leaks), and/or wear of the attaching pipe fittings.
Page 62 8.16. Trailer Wheels: Verify that the wheel to hub fit is correct and that the proper wheel lug nuts are being used. See Table 8.4 for lug nut type and Figure 8.6 for wheel to hub fit. Check the trailer wheel lug nut torque upon delivery of the new bulk abrasive blaster. On new units, the lugs must be retightened after each load and before reloading.
Page 63 8.18. Trailer Axle Maintenance: (yearly hub/drum inspection and removal) 8.18.1. Removal of Hub (1) Remove wheel. (2) Remove dust cap. (3) Remove cotter pin. (4) Unscrew the spindle nut counter-clockwise. (5) Remove spindle washer. (6) Remove hub/drum from spindle. (7) Inspect hub/drum for abnormal wear or scoring. Replace if needed. 8.18.2.
Page 64 8.23. Maintenance Schedules Quick Reference Charts Note: The following are minimum requirements for inspection and maintenance; however, the equipment should be inspected and serviced immediately if abnormal operation is detected. BULK ABRASIVE BLASTER MAINTENANCE SCHEDULE Item Function Required Daily Weekly Monthly Quarterly Blaster...
Page 65 BULK TRAILER MAINTENANCE SCHEDULE 3 Months 6 Months 12 Months Item Function Required 3,000 miles 6,000 miles 12,000 miles Test that they are Brakes Before every use operational Brake Adjust to proper operating Adjustment clearance Brake Inspect for wear and Magnets current draw Inspect for wear and...
Page 67: Drawings And Parts Lists
To insure the proper operation of the blast system only use Schmidt® original factory replacement parts furnished by an authorized Schmidt distributor. See Section 1.39 and Section 12.2.12. Copyright © 2019 Axxiom Manufacturing, Inc.
Page 95: Recommended Spare Parts Lists
10.0 Recommended Spare Replacement Parts Lists A) ELECTRIC and PNEUMATIC CONTROLS (see note below & refer to Section 9.0 drawings) Item No. Qty. Part No. Description Air Inlet Ball Valve, 3” 2401-511 2401-507 Blowdown Ball Valve, 1-1/4” Closure O-Ring, 10” 7007-519-03 2401-502 Drain Ball Valve, 1/4"...
Page 97: Troubleshooting
11.1.3. Both blast air and abrasive will not shut off (1) Twinline hoses to deadman valve (#12) are crossed. (2) Non-Schmidt deadman (#12) has been installed. (3) Control valves (#20 & #64) stuck in the “ON” position. (4) Blocked twinline hose.
Page 99 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 other outlets blasts normally). (2) Blocked control air hose to Thompson® Valve (#14) prevents opening. (3) Thompson Valve (#14) plunger stuck in closed position. (4) Trash plugging opening from tank to Thompson Valve (#14).
Page 100 11.3 Notes on Abrasive Flow Problems 11.3.1. Thompson® Valve operation If abrasive flow is a problem, remember; the Thompson Valve only opens and closes. The total travel to full open is approximately 3/4 of an inch. This can be quickly checked with the adjustment knob on the abrasive valve. For this procedure manually close the choke valve (#13) and the media shut-off valve to stop blast flow.
Page 101 (i.e. coalescing moisture separator, air-cooled aftercooler or deliquescent dryer). Contact a local authorized Schmidt® distributor or Axxiom Manufacturing, Inc. to locate one near you.
Page 102 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 103 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 104 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 105 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 106: Warranty And Reference Information
SCHMIDT 12.2 Warranty Policy 1. All SCHMIDT products are guaranteed to be free of defects in material and workmanship at time of shipment. Axxiom Manufacturing, Inc. warrants its products against defects in material and workmanship under normal and proper use for a period of ninety (90) days from the date of delivery.
Page 107 Schmidt®, the Schmidt stylized “S” logo, Thompson®, Microvalve®, MV2®, Tera Valve®, and Combovalve® are registered trademarks owned by Axxiom Manufacturing, Inc. Use of Schmidt, the Schmidt stylized “S” logo, Thompson, Microvalve, MV2, Tera Valve, and Combovalve trademarks without the written consent of Axxiom Manufacturing is strictly prohibited.
Page 108 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 109 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 110: Blasting Data Tables
(other than whip hose) and the air hose should be approximately three times the diameter of the orifice in the blast nozzle. Standard Schmidt blast units are rated for a maximum pressure of 125 psi or 150 psi. Refer to the pressure vessel nameplate for maximum operating pressure.

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