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DUSTLESS BLASTING DB1500 User Manual

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DB1500
/3000
User Manual
®
®
Warning: Do not use this equipment until you have read the manual
and understand the contents. *User safety is always a
top priority. However, the safety of an intended user
can only be protected if outlined precautions are read
and followed carefully. *International Distributors are
responsible for the proper translation of this manual.

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Summary of Contents for DUSTLESS BLASTING DB1500

  • Page 1 DB1500 /3000 User Manual ® ® Warning: Do not use this equipment until you have read the manual and understand the contents. *User safety is always a top priority. However, the safety of an intended user can only be protected if outlined precautions are read and followed carefully.

  • Page 2: Table Of Contents

    III. Preparing to Blast ………………………………..…………………………………….…..……11 Personal Protective Equipment………………………...……………………………………….11 Masking and Containment...…..………………………………………………………..……….11 ® ® Model DB1500 /3000 ……...…………..………………………………………………………..……….12 IV. Blast Pot Start Up ………………...…...………………………………………………………….13 i. Connect the Blast Hose, Compressor Air Hose, and Lines to the Blast Pot…….…………13 ii. Fill the Blast Pot with Abrasive and Water………………………………………..………..14 iii.
  • Page 3 IX. Machine Storage ……………...……………………………..…………………………………..…21 Storing the Machine in Cold Climate…………..……………………………………………….21 Blasting in Freezing Temperatures…………..………………………………………………….21 Machine Transportation………………………...……………………………………………….22 Moving the Blast Pot…………..…………………...…………………………………………….22 X. Maintenance …………..………………………………..……………………………………………23 Control Box………………………………….……………………………………………………..23 Pressure regulator…………………………………………………………………….…23 Control box Parker valve……………………...……………………………………….…23 Blast Pot Pressure Regulator………………….…………………………………………………..24 Filter Regulator………….……………...………………………………………………………….24 Blast Hose…………….……………………..…………………………...…………………………24 General Blast Pot Maintenance…………….………………...………………………...…………25 Flushing the blast pot…………………………………..…………………………………25 Blast wear parts…………………………………….…..…………………………………26 Pinch Hose Maintenance…………….………………...………………..…………..……………27...

  • Page 4: Introduction

    This manual covers the start up, operation, storage, maintenance, and troubleshooting, for a ® ® DB1500 /3000 blast pot. Intended users must read and understand the contents of the instructions before operating their machine and its accessories. The intended user should be able to safely operate the blast machine and be aware of the hazards associated with blasting.

  • Page 5: Blast Pot Warranty

    MMLJ, Inc. receipt of payment or acceptable arrangements for payment. Except, as expressly set forth in this warranty, MMLJ, Inc. makes no other warranties, expressed or implied. This is the only express warranty applicable to Dustless Blasting® branded products. MMLJ, Inc. does not assume, nor authorize anyone to assume for it any other express warranty.

  • Page 6: Safety Overview

    Air filter. Used with NIOSH-approved respiration ® ® Blast pot. The DB1500 /3000 is designed to blast for equipment to remove air contaminants. Follow the approximately two to three hours. Inspect the machine, manufacturers requirements for replacing these filters as nozzles, hoses, and couplings before operating.

  • Page 7: Abrasives

    II. ABRASIVES DANGER: No dust is safe to breathe. Abrasives may contain toxic materials that are hazardous to persons in the blasting area when inhaled. Do not use abrasives containing more than one percent crystalline (free) silica. Inhaling crystalline silica sand can cause silicosis, lung cancer, and breathing problems to exposed persons.

  • Page 8: Media Comparison Charts

    Density. Knowing the weight or bulk density of an abrasive can help an operator choose the appropriate abrasive for the job. The density is measured in pounds per cubic foot, so an abrasive with a bulk density of 75 lb/ft is less dense than a sample of 145 lb/ft .
  • Page 9 Figure 4. Wet or Dry Blasting Abrasive Bulk Surface Surface Description Hardness Velocity Density Profile Removal Angular for fast 40 – 65 Medium Steel Grit stripping and aggressive 260 lb/ft High etch Moderate fast cleaning Spheres designed for 40 – 51 Steel Shot 230 lb/ft No etch...

  • Page 10: Abrasive Fill Levels

    Abrasive Fill Levels ® ® Note: The DB1500 /3000 has a maximum hold of: 75 gal of clean water • 750 lb of abrasive (~40/70 mesh • size) 100 oz of Rust Inhibitor • The blast pot does not require a maximum fill for operation. If the maximum fill is not needed for a job, fill the machine according to estimated blast time.

  • Page 11: Preparing To Blast

    III. PREPARING TO BLAST Personal Protective Equipment DANGER: Failure to maintain proper PPE can result in the serious injury or death of the operator or bystanders. Loud noise generated by blasting can cause hearing damage. Everyone in the area must use proper hearing protection. It is the employer’s responsibility to train employees to identify hazardous substances and to provide suitable policies, procedures, monitoring, recordkeeping, and PPE.

  • Page 12: Model Db1500 ® /3000

    ® ® Model DB1500 /3000 ® ® The figures below show commonly referenced parts of the DB1500 /3000 blast pot mentioned in this manual.

  • Page 13: Blast Pot Start Up

    IV. BLAST POT START UP i. Connect the Blast Hose, Compressor Air Hose, and Lines to the Blast Pot Attach the blast hose to the pinch hose Pneumatic blast pot. Fasten the twin line at the top of the blast pot and insert the to the control box safety pins.

  • Page 14: Fill The Blast Pot With Abrasive And Water

    ii. Fill the Blast Pot with Abrasive and Water DANGER: Do not use abrasives with more than one percent crystalline silica. Breathing crystalline silica dust can cause silicosis, a potentially fatal and damaging lung disease. Refer to the abrasive’s Safety Data Sheet (SDS) to identify potentially toxic substances in the media.

  • Page 15: Turn On The Compressor

    iii. Turn on the Compressor Caution: Reference the instruction manual for the selected compressor model before operating. Allow the compressor to idle and warm up for about 15-30 seconds. iv. Pressurize the Blast Pot Caution: Pressurize the blast pot before starting the active blasting process. When the machine pressurizes, the abrasive lever on the blast pot will pop up.

  • Page 16: Active Blasting

    V. ACTIVE BLASTING Danger: Uncontrolled blast stream and high-velocity abrasive particles can inflict serious injury. Always maintain nozzle control and point the blast nozzle in the direction of the blast surface only. Make sure the blast hose is securely fastened to prevent detaching during operation.

  • Page 17: Blast Pot Shut Down

    VI. BLAST POT SHUT DOWN Caution: DO NOT turn off the compressor when starting the shut down process. Failure to leave the compressor running will cause a backflow of air, water, and media into the system and damage the machine. While the compressor is running, close the Let the pot fully depressurize before air inlet-shutoff valve.

  • Page 18: In Process Adjustments

    VII. IN PROCESS ADJUSTMENTS There are three recommended areas of adjustment to aid in an efficient blasting process. Abrasive flow rate • Blasting pressure • Stand-off distance • Adjusting Abrasive Flow Rate The desired flow rate of media from the blast pot may change from surface to surface. There are adjustments that can be made throughout the blasting process to maximize media flow rate.

  • Page 19: Decreasing Media Flow

    Decreasing media flow Fully depressurize the blast pot before decreasing media flow. Decrease the amount of abrasive in the blasting output by turning the abrasive valve in quarter-turn, clockwise increments. Adjusting Operating Pressure Finding the optimal pressure is important for maximizing operator efficiency while protecting the blasted surface.

  • Page 20: Transitioning From Wet To Dry Blasting

    VIII. TRANSITIONING FROM WET TO DRY BLASTING Caution: ® ® The DB1500 /3000 is suitable for wet and dry blasting. To dry blast, an air drying and cooling system is required. To prepare the blast pot for dry blasting: 1. Blast all media and water out of the machine.

  • Page 21: Machine Storage

    IX. MACHINE STORAGE When leaving a blast pot idle for long periods of time, be sure to completely blast the water and media out of the tank or follow the storage procedure below. See Figure 7 and 8 in “Flushing the Blast Pot”...

  • Page 22: Machine Transportation

    Machine Transportation DANGER: Make sure the blast pot is empty and the abrasive lever is locked before attempting to transport the machine. Use lift equipment that is suitable for weight heavier than the machine and attachments. Securely attach the machine to transportation device such as a pallet or vehicle.

  • Page 23: Maintenance

    X. MAINTENANCE DANGER: Do not attempt maintenance on a pressurized machine. Control Box Pressure regulator The control box’s pressure regulator comes factory set at 80 PSI. Make sure to adjust the regulator until the PSI is back at 80 if the pressure is ever changed. Caution: Do not attempt to change the PSI of the control box’s pressure regulator from 80 PSI.

  • Page 24: Blast Pot Pressure Regulator

    Blast Pot Pressure Regulator Be sure to periodically lubricate the threads on the pressure regulator knob with a lubricant such as lithium grease. Filter Regulator The filtered moisture and debris will collect at the bottom of the regulator if not vented through the screw.

  • Page 25: General Blast Pot Maintenance

    General Blast Pot Maintenance Flushing the Blast Pot Regularly flushing the pot avoids potentially damaging buildup from accumulating on the walls of the machine. About once a month, follow the procedure below to properly flush the blast pot. 1. Fully depressurize machine by opening the air inlet-shutoff valve and closing the blow down valve.

  • Page 26: Blast Wear Parts

    Blasting Wear Parts Certain parts wear faster than others and will require regular maintenance and inspection depending on the method and abrasive used to blast. These items should be inspected for damage or wear weekly. Note: Depending on how much dry blasting is done, these parts may have to be replaced sooner or later than the recommended time.

  • Page 27: Pinch Hose Maintenance

    Pinch Hose Maintenance Warning: Make sure to completely replace the pinch hose after about 40 hours of use or four rotations. When replacing the hose, make sure there is a flush square cut. Failure to do so could result in pinch hose malfunctioning. A dysfunctional pinch hose can result in operator or bystander injury.

  • Page 28: Removing The Brass Couplings From An Old Hose

    Removing the Brass Couplings From an Old Hose 1. Remove the screw on the coupling using a Phillips head screwdriver or drill. 2. Unscrew the brass coupling from hose turning counterclockwise. A bar or rod may be needed to loosen this piece. Attaching the Brass Couplings to the New Pinch Hose 1.

  • Page 29: Preventative Maintenance

    Preventative Maintenance The following daily, weekly, and monthly maintenance suggestions should be used as a general guide only. Comprehensive maintenance will vary for each machine. Daily Maintenance The operator should perform daily checks on all parts of their machine to ensure safety and operational ability of components.

  • Page 30: Monthly Maintenance

    Monthly Maintenance General parameters for checking the items below is about every 40 hours. MMLJ Parts Replace the pinch hose monthly, or after it has been rotated four times. • Lubricate the threads of the pressure regulator knob with a lubricant such as lithium •...

  • Page 31: Troubleshooting

    XI. TROUBLESHOOTING Media Buildup Inside the Blast Pot Adjust the vibrator valve On the left side of the control box, a small brass petcock valve controls the vibrator speed. Make sure this vibrator valve is open during active blasting and adjusted until there is maximum vibration of the machine head.

  • Page 32: Pinch Valve Is Not Opening Or Closing (Pneumatic)

    Pinch Valve is Not Opening or Closing (Pneumatic) Caution: Open the blow down valve and close the air inlet-shutoff valve before beginning the process below. Check the following Does the pressure gauge on the Are all fittings tightly secured to Is air bleeding out of the bottom left side of the control the deadman and the back of the...

  • Page 33: Appendix

    XII. APPENDIX...
  • Page 35 Item No. Description Part No. Stock No. Qty. Outlet Elbow Assembly Complete M-17 72974/001 Outlet Elbow Cap Bolts (4) M-17-D 82563/001 Outlet Elbow Cap M-17-C 131054/001 Outlet Elbow Cap Gasket M-17-G 131227/001 Outlet Elbow Insert Gasket M-23-G 131147/001 Outlet Elbow Insert M-23 73602/001 Outlet Elbow Body...
  • Page 36 Item No. Description Part No. Stock No. Qty. Pop-up Cylinder Screw M-19-N 68810/001 Handway Nut FM-66-N 43625/001 Handway Cross Bar FM-66-C 74439/001 Handway cover FM-66-P 73604/001 Handway Gasket FM-66-G 73605/001 1"x2" Adjustment Nipple FM-19-P 131132/001 1"x3/4" Reducing Elbow FM-19-R 131842/001 3/4"x4"...
  • Page 37 Item No. Description Part No. Stock No. Qty. 1-1/4" x 1" Bell Reducer - SS 131874/SS 1" Close Nipple - SS RC-24-SS 727821/SS 2" x 3" Nipple - SS 134802/SS 2" Regulator 132055/004 2" Crowfoot 74470/001 2" Crowfoot Gasket 74908/001 1/4"...

  • Page 38: Additional Resources

    Thank you for choosing Dustless Blasting. We want the transition into building your business to be as seamless and safe as possible. The team creates all of our manuals with the customer experience in mind. We’re always looking to improve! Please scan the QR code below to give direct feedback...
  • Page 39 The Future of Surface Preparation ® MMLJ, Inc. Phone: 800-727-5707 Email: support@dustlessblasting.com 5711 Schurmier Rd. International: +1 713-869-2227 www.dustlessblasting.com Houston, TX 77048 Fax: 713-868-8041...

This manual is also suitable for:

Db3000

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