Schmidt ADS 250 Operation And Maintenance Manual

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ACS/ADS AIRPREP SYSTEM

OPERATION AND MAINTENANCE MANUAL

August 2020

SAVE THIS MANUAL AND MAKE AVAILABLE

TO ALL USERS OF THIS EQUIPMENT!

Manual Part Number 7200-260 rev10-20

(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 ACS/ADS AIRPREP SYSTEM OPERATION AND MAINTENANCE MANUAL August 2020 SAVE THIS MANUAL AND MAKE AVAILABLE TO ALL USERS OF THIS EQUIPMENT! Manual Part Number 7200-260 rev10-20 (Available for downloading from SchmidtAbrasiveBlasting.com) Copyright © 2020 A 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 Website...
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
Manual Use, Explanation of Safety Symbols, and Glossary This manual contains information needed to operate and maintain your AirPrep System. Read this entire operations and maintenance manual before using your AirPrep System. 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
0.1(a) and 0.1(b) for images of the warning decals. Refer to Figures 0.2(a), 0.2(b) and 0.2(c) for the locations of these warning decals. Qty. Part no. Description Hazard 7031-019 Air Prep System Not Applicable 7031-033 ADS 250 7031-034 ADS 400 7031-035 ADS 750 7031-036 ADS 950 Not Applicable 7031-037 ADS 1200...
Page 5 2B) 7031-XXX 3) 7031-001 4A) 7031-007A (4.5” x 8.5”) 4B) 7031-007B (3” x 6”) 5) 7031-017 6) 7031-018 7) 7031-057 8) 7031-081 9) 7031-082 Figure 0.1(b) – Warning decal summary Copyright © 2020 Axxiom Manufacturing, Inc.
Page 9: Table Of Contents
Table of Contents Section Page Preface Manual Use, Explanation of Safety Symbols, and Glossary Warning Decal Identification and Location Rules for Safer Operation Specifications and General Information System Requirements Abrasive Blast System General Operation AirPrep System General Operation Pre-operation Procedures Operating Instructions Maintenance and Inspection Instructions Drawings and Parts Lists...
Page 10: 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 11 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 12 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 and 1926.101. Loud noise is generated 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 13 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 14 1.25. NEVER OPERATE BEYOND ALLOWABLE TEMPERATURE RANGE. Do Not operate this equipment above the maximum allowable temperature at the allowable pressure or below the minimum design metal temperature (MDMT) shown on the pressure vessel nameplate. The characteristics of the pressure vessel metal are weakened when the temperature is outside the operating range.
Page 15 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 16 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 17 1.49. DO NOT CYCLE AIRPREP SYSTEM FAN. AirPrep Systems fan and drive motors are designed for continuous operation. Do Not alter to a cycled fan mode. 1.50. ALLOW PROPER CLEARANCE. Do Not install this equipment where airflow to aftercooler fan will be restricted. For proper air flow, a minimum of 12"...
Page 18: Specifications And General Information
Specifications and General Information Notes to Distributors and Owners 2.1.1. Verify that the operation and maintenance manual is included with the AirPrep System when it is received. Verify that the operation and maintenance manual is included with the AirPrep System when it is delivered to the purchaser. 2.1.2.
Page 19 National Board Number Vessel Information 2.4.1. All pressure vessels used in Schmidt AirPrep Systems 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 20 Do Not connect slings or other lifting devices to any other location other than the lifting eyes. All AirPrep Systems larger than ACS/ADS 250 are equipped with forklift pockets as a part of the skid frame. Only qualified personnel should load and unload this equipment using fork trucks with a sufficient load rating.
Page 22 Aftercooler System (ACS) Dimensional Specifications PART NO. MODEL HEIGHT WIDTH LENGTH INLET OUTLETS WEIGHT ELECTRIC in(mm) in(mm) in(mm) (NPT) (NPT) lbs. (kg) MOTOR MOTOR (1) 2", (2) 1 ½" ACS 250P 1300-021P 1300-027P 54 (1372) 24 (610) 35 (889) 2" 290 (132) ACS 400P 1300-041P...
Page 23: System Requirements
System Requirements Compressed Air Requirements Blast nozzle The blast nozzle size and blast pressure determine the compressed air requirements. Available air flow capacity and/or air compressor size must be considered before selecting the blast nozzle size. An air source dedicated to the abrasive blast system is preferred to reduce system pressure drops and back flow of air.
Page 24 Blast System Air Quality AirPrep Systems are equipped with an inlet filter/separator to remove debris and condensed moisture from the incoming air flow; however, if the air source contains an excessive amount of debris, it may be necessary to install a preliminary filter upstream of the AirPrep System inlet. Excessive contamination of the incoming air can clog the heat exchanger of the AirPrep System and cause expensive damage to the system.
Page 25 3.10 Personal Protective Equipment (PPE) AirPrep Systems are designed to be used with abrasive blasting equipment; therefore, operators may be exposed to hazards that may not be directly related to the AirPrep System. Abrasive blasting has many hazards that may cause injuries to operators. To minimize risk of injury to operators, each must be supplied with and required to use Personal Protective Equipment.
Page 26 3.11 Pressure Relief Valve Installation Do Not operate this equipment without a pressure relief device installed to protect the AirPrep System from over-pressurization. The ASME Code requires that all vessels be operated with pressure relief devices in place. If the AirPrep 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 27 3.12 INSTALLATION CHECKLIST (Photocopy this page to use as a worksheet) □ Accessories: confirm receipt as purchased with the AirPrep System. □ Inspect AirPrep System: check for possible damage during shipment. See Section 8.0 for inspection instructions. □ Clean AirPrep ADS System: remove handway cover and check for debris inside. If Replace handway cover per instructions in Section 6.3.
Page 28: Abrasive Blast System General Operation
AirPrep System General Operation The function of the Schmidt® AirPrep System is to reduce the moisture content of the compressed air used in an abrasive blast system or for other compressed air requirements. The AirPrep System is supplied air from an air compressor which will then supply air to the blast nozzle. The abrasive blast stream through the blast nozzle is used for removing rust, paint, or other unwanted surface defects.
Page 29: Airprep System General Operation
AirPrep System General Operation See Figure 5.1 to help understand the general operation of an AirPrep System. Do not attempt to operate the AirPrep System before reading all sections of this manual and following all setup procedures. See Sections 5.1 through 5.14 and Section 6.0. An AirPrep System is designed to cool, clean and dry compressed air for use in abrasive blasting equipment.
Page 31 Air Motor (radiator fan) The air motor (#5) is a rotary type motor operated by compressed air. The expansion of the operating air during normal operation creates a cooling effect. Therefore, the temperature of the air motor will not exceed the higher of the surrounding atmosphere or the air input temperatures. The vanes of the air motor take up their own wear and will last 5,000-15,000 hours depending upon speed, method of oiling, operating pressure and the maintenance performed on the motor.
Page 33 Separator Tank After the compressed air leaves the aftercooler, it enters the separator tank (#12). The separator tank allows the compressed air to expand causing moisture condensation. The air enters the tank at a low elevation through a tangential inlet. The cyclonic movement causes the water droplets in the air to drop to the bottom of the tank.
Page 34 5.12 ADS System Air Outlets On ADS Dryer Systems the air outlets are located on the after-filter (#2). There are three air outlet ports: one primary outlet and two smaller auxiliary ports. Portable models only have one air outlet. Refer to Section 2.8 for the outlet sizes. There are no fittings or ball valves provided with the outlets.
Page 35: 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 Operation and Maintenance Manual. The AirPrep System is a pressurized vessel. Propelled objects will cause serious injury or death. Depressurize vessel before performing any maintenance.
Page 37 6.1.6. Units having electric aftercooler fan motors must be installed by qualified personnel. Follow manufacturer’s recommendations. Power connections to AirPrep System with electric motors expose operators to high electrical voltages. Contact with high electrical voltages can result in serious injury or death.
Page 38 AirPrep System Depressurizing Procedure (Blowdown) 6.2.1. Close the air compressor outlet ball valve (#44, provided by user). See Figure 6.2. The air compressor ball valve is not part of the AirPrep System and is not provided with the unit. It is the responsibility of the user to verify that an air compressor outlet ball valve is installed so the AirPrep System can be isolated from the air compressor.
Page 39 6.2.6. Close the AirPrep System inlet ball valve (#46, provided by user). The air inlet ball valve is not provided with most AirPrep System. It is the responsibility of the user to install the inlet ball valve so AirPrep System can be locally isolated from the compressed air source.
Page 40 6.3.13. Periodically check for leaks. *Note: Contact Axxiom Manufacturing or an Authorized Schmidt distributor and request information on the new SureFit™ Handway Gasket (patent pending) that eliminates the difficulty of aligning the gasket. Scan the QR Tag on the left to view a short video.
Page 41 Figure 6.4 (a) – Handway Assembly Figure 6.4 (b) – Handway Components 6” x 8” Handway Dimensions Component Weld Ring 6-5/8” 8-1/2” Handway Cover 7-5/8” 9-3/4” Handway Gasket 7-3/4” 9-3/4” SureFit™ Gasket 8-1/16” 10-5/16” Handway Crab 2-3/8” 8-3/4” Square Head Bolt 3/4”-10 UNC 4-1/2”...
Page 42: Operating Instructions
Operating Instructions Filling the AirPrep Air Dryer System with Deliquescent/Desiccant (ADS Systems only) 7.1.1. The AirPrep ADS System must be completely depressurized before filling with deliquescent 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 44 7.2.5. If the unit has an electric aftercooler motor, press the “Start” button to begin cooling fan operation, then skip to step 7.2.8. If the aftercooler has an air motor, open the air motor on/off ball valve (#13). 7.2.6. Adjust air pressure regulator (#14) to the required pressure. See Section 11.0 for correct air motor inlet pressure setting.
Page 46: Maintenance And Inspection Instructions
Maintenance and Inspection Instructions The AirPrep System is a Pressurized Vessel. Propelled objects will cause serious injury or death. Depressurize vessel before performing any maintenance. See Section 6.2. 8.1. AirPrep System Pressure Vessel: The ASME Code is a standard covering materials, design, fabrication, and installation.
Page 47 Failure to properly lubricate the air motor as detailed above will result in costly motor failure. Note: Two types of lubricators have been used in Schmidt® AirPrep Systems. Current production units are equipped with “oil-fog” lubricators (Style MP). Systems manufactured prior to September 2016 are equipped with “micro-fog”...
Page 48 8.5.7 Air Motor Exhaust Muffler: Inspect the air motor exhaust muffler monthly. Dirt and grime accumulation on the exhaust element can restrict air flow and cause a reduction of power output from the air motor. Remove the muffler and clean with a degreasing agent. 8.5.8.
Page 49 8.8. Blast and Air Hose Couplings: All air hose couplings have pin holes that align when connected. To protect against accidental hose disconnections safety pins must be installed through these holes. Each hose connection must also include a hose whip check that will hold the hose if there is an accidental disconnection.
Page 50 8.13. Maintenance Schedule Quick Reference Chart AIRPREP AIR DRYER SYSTEM 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 51: Drawings And Parts Lists
To ensure the proper operation of the AirPrep System only use Schmidt® original factory replacement parts furnished by an authorized Schmidt distributor. See Section 1.39 and Section 12.2.12. Copyright © 2020 Axxiom Manufacturing, Inc.
Page 68: Recommended Spare Parts List
10.0 Recommended Spare Parts Lists A) Pneumatic and Electric Fan Motor Systems (see note below & see Section 9.0 drawings) ITEM PART # DESCRIPTION 1 & 2 4211-999 Crowfoot gasket (may not apply to some systems) 2401-502 Pre-filter/After-filter drain ball valve, 1/4" (ACS/ADS 400-2500 systems) 7000-001-18 Handway gasket, 6”...
Page 69: 11.0 Airprep System Technical Data And Troubleshooting
Drip rate is the recommended drops of oil that enters the air motor per minute based on the CFM. Two types of lubricators have been used in Schmidt® AirPrep Systems. Current production units are equipped with “oil-fog” lubricators (Style MP). Systems manufactured prior to September 2016 are equipped with “micro-fog”...
Page 70 11.3 TABLE 3 TROUBLE SHOOTING GUIDE FOR AIR MOTORS SYMPTOM WON’T RUN RUNS GOOD THEN REASON LOW TORQUE LOW SPEED RUNS HOT SLOWS DOWN AT ALL DIRT OR FOREIGN MATERIAL INTERNAL RUST MISALIGNMENT INSUFFICIENT AIR PRESSURE AIR SUPPLY LINE TOO SMALL RESTRICTED EXHAUST POOR LUBRICATION JAMMED MACHINE...
Page 71: 12.0 Warranty And Reference Information
The following sections are to be used as a guide in determining warranty policies and procedures for SCHMIDT® products. It is to be used in determining whether a warranty is justified and as a procedural guide in completing a SCHMIDT warranty claim.
Page 72 TO THE SCHMIDT PRODUCTS SOLD PURSUANT THERETO. 12.3 Trademarks, Patents, and Proprietary Statements 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 73 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 74 12.5 Surface Preparation Information Sources he 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: 1-877-281-7772 Website: www.sspc.org The Society for Protective Coatings 800 Trumbull Dr. Pittsburg, PA 15205 National Association of Corrosion Engineers (NACE) develops test methods and recommended practices on surface preparation techniques and coatings.
Page 76: Blasting Data Tables
Association of Corrosion Engineers’ data suggests that for each 1 psi reduction in nozzle pressure, there is a 1.5% production loss. Pressure drop through a Schmidt® blast unit is normally less than 1 psi, while blast units manufactured by some of our competitors have pressure losses as high as 12 psi resulting in an 18% loss of production.

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Schmidt ADS 250 Operation And Maintenance Manual

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Summary of Contents for Schmidt ADS 250

Page 3: Manual Use, Explanation Of Safety Symbols, And Glossary

Page 4: Warning Decal Identification And Location

Page 9: Table Of Contents

Page 10: Rules For Safer Operation

Page 18: Specifications And General Information

Page 23: System Requirements

Page 28: Abrasive Blast System General Operation

Page 29: Airprep System General Operation

Page 35: Pre-Operation Procedures

Page 42: Operating Instructions

Page 46: Maintenance And Inspection Instructions

Page 51: Drawings And Parts Lists

Page 52: Acs 250P/400P Aftercooler Systems (Air Motor)

Page 54: Acs 400-2500 Aftercooler Systems (Air Motor)

Page 56: Acs 250P/400P Aftercooler Systems (Electric Motor)

Page 58: Acs 400-2500 Aftercooler Systems (Electric Motor)

Page 60: Ads 250P/400P Air Dryer Systems (Air Motor)

Page 62: Ads 400-2500 Air Dryer Systems (Air Motor)

Page 64: Ads 250P/400P Air Dryer Systems (Electric Motor)

Page 66: Ads 400-2500 Air Dryer Systems (Electric Motor)

Page 68: Recommended Spare Parts List

Page 69: 11.0 Airprep System Technical Data And Troubleshooting

Page 71: 12.0 Warranty And Reference Information

Page 76: Blasting Data Tables

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Schmidt ADS 250 Operation And Maintenance Manual

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