Page 1
Model 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII October 2008...
Page 2
FORWARD Blastrac is pleased that you have selected this Blast Cleaning System for your surface preparation requirements. This environmentally safe, closed-cycle, surface preparation machine has been designed and built for abrasive blast cleaning of horizontal surfaces. This manual has been prepared to assist the operator and the maintenance personnel in understanding the machine so that it may be operated in the most efficient manner and maintained in the best condition.
Page 3
Receipt of Machine Examine the shipment carefully for possible damage that might have occurred while in transit. If any damage is noted, notify the transportation carrier immediately and advise Blastrac.
Page 5
All operating and maintenance personnel must observe all warnings and precautions that are listed in this manual for the Model 1-10DMKIII, 1-10DSMKIII, 1-15DMKIII, 1- 15DSMKIII and 654 Dust Collector. All safety labels posted on the machine must be followed as well as the safety program instituted by your individual management.
Work areas must be dry and clean (no loose debris) before cleaning can begin. Maintain all guards in place - Blastrac machines are equipped with guards or coverings for parts that may be hazardous.
Page 7
& 1-15D/1-15DSMKIII Safety Precautions 1.2 Mechanical 1. Before performing any type of maintenance on your Blastrac equipment, be sure that all moving parts have completely stopped. The blast wheel, for example, may continue to rotate for a period of time once it has been deactivated.
Page 8
8. Obey all safety labels posted on the machine and all information posted where the machine is being operated. 9. Do not operate USF/Blastrac machinery in the rain or when heavy moisture is present. Do not expose the abrasive supply to any type of moisture. Sticky, tar related and rubber surfaces should be avoided when using Blastrac 1.3 Electrical...
Page 9
Sustained improper motor rotation can damage machine components. Your Blastrac Blast Unit and 654 Dust Collector can be operated on 208, 230, 460 and 480 volt, three phase, 60-Hertz power ONLY. Do not attempt to operate this equipment...
Page 10
& 1-15D/1-15DSMKIII Safety Precautions 1.4 Dust Collector and Ventilation All Blastrac abrasive blast equipment must be properly ventilated to be environmentally effective. This benefits the operator, machine efficiency and contributes significantly to better wear and less maintenance. The dust hoppers of the dust collectors should be kept empty. The importance of checking the dust level during normal working conditions cannot be over-stressed.
Page 12
16.5 AMP 16.5 AMP 22.5 AMP 2. The operator shall provide personnel who have been trained by a Blastrac Technician for the operation and maintenance of Blastrac equipment. 3. The operator shall provide the necessary blasting media in accordance with the recommendations of a Blastrac technician so that the machine will operate at maximum efficiency.
Page 13
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Operator Responsibilities 2.1 Cont’d 6. The operator shall maintain an inventory of “wear parts” as outlined in this manual. 7. The operator shall dispose of all dust collector refuse. 8. The operator shall provide the following tools and accessories: Hammer Screwdrivers Wrench Set...
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function Section 3 Description and Function - General Blast Units – Abrasive Cleaning Head Blast Units – Abrasive Control Valve Blast Units – Rebound Plenum Blast Units – Separator Blast Units – Abrasive Seals Blast Units –...
Page 15
Description and Function 3.1 Description and Function – General The Blastrac equipment series described herein includes the 1-10DMKIII, 1-10DSMKIII, 1- 15DMKIII and the 1-15DSMKIII blast units. Each of these models is used in conjunction with the 6-54 Dust Collector. Each combination comprises a horizontal surface preparation, closed cycle, shotblasting system.
Page 16
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.2 Continued The blast wheel is equipped with a cast in place impeller for easy maintenance. This impeller pre-accelerates the abrasive to the wheel blades in controlled portions. Abrasive that is gravity fed to the center of the wheel is accelerated in segments and directed through the control cage.
Page 17
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.5 Blast Units – Separator Once the contaminated abrasive leaves the rebound plenum, it enters the separator and immediately encounters the deflector plate. The deflector plate slows the abrasive down even more before it enters a tray at the bottom of the deflector plate. The contaminated abrasive hits the abrasive already at the bottom of the plate and effectively absorbs any residual force left in the moving mixture.
Page 18
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.8 Blast Units – Electrical Control Panel This panel was designed to safely operate in the range of 3 phase, 60 Hertz voltages (208, 230, 460 and 480) typically available in the U.S. This control panel features “Auto Voltage Sensing”...
Page 19
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.8 Continued Phase Monitor – Provides phase sequence (rotation) and phase loss protection. Will not allow the system to start unless rotation is correct and all three phases are present. Analog Ammeter – Provides readout of how much current the wheel motor is drawing. This allows the operator to more precisely monitor and control abrasive flow.
Page 20
Blastrac does not recommend using more than 50 feet of hose on concrete surfaces. Consult with your Blastrac representatives if you have a particular application that requires a longer exhaust hose.
Page 21
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.10 Continued The dust that was trapped on the external surface of the filters is periodically removed by pulsing the filters with an internally supplied burst of compressed air. This momentary pulse of air allows the dust to fall into a hopper at the bottom of the filter chamber. Two filters are pulsed at a time, in sequence, determined by a timer board located in the control panel.
Page 22
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.14 Dust Collector – Pulse Pressure System A direct driven, 3/4 horsepower, maintenance free air compressor with external pressure regulation is mounted beneath the control panel on the dust collector. The pressure of this system is determined by the setting of the unloader valve located on the pressure side of the compressor.
Page 23
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.16 Continued After proper rotation is established, the operator has only to operate the “Voltage Selector” switch to the “Low” or “High” position as indicated to start the equipment. This “Voltage Setup” switch connects the windings of the motor(s) and control power transformer for “High”...
Page 24
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.16 Continued Compressor Start / Stop Buttons – Allows the operator to start or stop the compressor with 120 volt control voltage circuitry. Blower Start / Stop Buttons – Allows the operator to start or stop the blower with 120 volt control voltage circuitry.
Page 25
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Description and Function 3.17 Continued The dust-laden air from the air wash is directed through the separator and into the flexible hose. The hose delivers the contaminated air to the dust collector where the air is filtered and returned to the atmosphere.
Page 27
Pay close attention to all safety instructions, dangers, warnings and cautions. Also, Blastrac highly recommends that all operating and maintenance personnel receive a thorough training regimen from an authorized Blastrac representative before attempting to operate or maintain this equipment. Start-Up Warning: Machine power should be disconnected before any and all machine inspections.
Page 28
14. Check the area you are about to clean. Be sure that it is free of all debris that can clog or damage the equipment. Be sure that the surface is moisture free. Blastrac machinery is designed to work on clean, dry surfaces only.
Page 29
If the green “Proper Rotation” light is on, the operator may proceed. NOTE* New Blastrac machines are factory tested to assure both machines have the same motor rotation. Changing the two hot leads at the power source will reverse the motor rotation of all three electrical motors.
Page 30
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Start-Up Procedures 4.1 Continued be started. NOTE: Site power during motor startup must not drop below the minimum voltages (187 volts or 414 volts). CAUTION: BE SURE ALL ELECTRICAL DISCONNECTS ARE LOCKED IN THE “OFF” POSITION AND THAT ALL ROTATING PARTS ARE FULLY STOPPED BEFORE WORKING IN PANELS.
Page 31
Caution: Do not allow any type of equipment to run over the power cable or the exhaust hose. Always avoid long power cord extensions. Contact a Blastrac representative for extension cord details.
Page 32
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Start-Up Procedures 4.2 Continued Blasting during a turn will create an uneven profile. Once an area has been cleaned, the blast unit and the dust collector can be moved to an adjacent location to continue cleaning.
Page 33
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Setting the Correct Blast Pattern Section 5 Setting the correct blast pattern...
Page 34
There are four major factors that can affect the blast pattern. They are: 1. Wheel Rotation - The blast wheel must be rotating in the proper direction indicated on the housing that surrounds the blast wheel. Most Blastrac machines rotate in a counter-clockwise direction when looking at the machine from the operator’s position.
Page 35
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Setting the Correct Blast Pattern 5.1 Cont’d indicated in the illustrations. The resultant-cleaning path will determine the final setting. Note: (Machines that rotate in a clockwise direction, such as the Model 1-20D, will have an initial setting between 12:30 and 2:30.) These settings can vary with the abrasive size and the surface being cleaned.
Page 37
• Steel surface cleaning: 1 to 3 (slow speeds 6 to 21 ft/min) 5. Exhaust Hose Length - 50 feet of 5-inch diameter exhaust hose; longer or shorter sections of hose may affect abrasive consumption or abrasive cleaning. Contact your Blastrac representative before changing the exhaust hose length.
Page 38
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Equipment Calibration 6.1 Continued 6. Dust Collector Pulse Timer - Set for approximately 10 seconds for concrete cleaning; 15 seconds for steel cleaning. 7. Compressor Pressure Setting - 80 PSI max. The unloader adjustment determines pressure. (30 PSI drop for Pulse) 8.
Page 40
Wear Parts Wear Parts Certain portions of the Blastrac are continuously exposed to high velocity abrasive. These areas and their corresponding parts must be periodically inspected for wear and erosion to keep from damaging components that are not normally exposed to the abrasive blast.
Page 41
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Blast Wheel Replacement Section 8 Blast Wheel Replacement Blast Motor Belt Replacement/Adjustment...
Page 42
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Blast Wheel Replacement 8.1 Blast Wheel Replacement WARNING: ALL ELECTRIC POWER MUST BE DISCONNECTED AND ALL ROTATING PARTS MUST BE COMPLETELY STOPPED BEFORE ATTEMPTING THIS PROCEDURE. 1. Release the two locking cams that secure the feed spout and slide the straps away. Remove the feed spout.
Page 43
Blastrac parts are supplied in a state of accurate balance with machined surfaces for safe, reliable operation.
Page 44
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Blast Wheel Replacement 8.2 Cont’d 5. To remove the belt, rotate the hex head bolt (ITEM 5) on the eccenter sleeve (ITEM 4) counter-clockwise until the socket head screw (ITEM 3) is in the 6:00 position or directly below the hex head bolt (ITEM 5).
Page 45
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Blast Wheel Replacement 8.2 Cont’d FIGURE 8.1 Belt Tension Requirements Belt Tension The correct belt tension is important for the life of the belt, sheaves and wheel bearing unit. Too much belt tension will reduce the operating life of these components.
Page 46
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Blast Wheel Replacement 8.2 Cont’d 9. Replace the belt guard. NEVER OPERATE THE MACHINE WITHOUT THE BELT GUARD IN PLACE. 10. Check the belt tension after 50 hours of run time after replacing the belt. This “run-in”...
Page 48
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Lubrication 9.1 Lubrication The bearing unit that is located directly behind the blast wheel outside the blast housing must receive periodic lubrication. This unit operates at a relatively high temperature (200 degrees Fahrenheit) and requires the use of a high temperature, lithium based grease.
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Troubleshooting 10.1 Troubleshooting Note: All operators and maintenance personnel should read and understand the entire Operating Instructions Manual before attempting to operate or maintain this machine. Pay close attention to all safety instructions, dangers, warnings and cautions.
Page 51
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Troubleshooting 10.1 Continued Trouble Probable Cause Remedy Increased cleaning time. Improper abrasive feed to Check ammeter reading. Low wheel. reading indicates insufficient abrasive getting to wheel. Storage hopper. Check abrasive level. Contaminated abrasive. Abrasive may contain substantial percentage of fines and contaminants.
Page 52
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Troubleshooting 10.1 Continued Trouble Probable Cause Remedy Excessive wear on blast Improper setting of Abrasive is being misdirected housing rebound control cage. into internal components chamber / liners. instead of work area. Check blast pattern and readjust. Abrasive leakage.
Page 53
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Troubleshooting 10.2 Ventilation System (6-54 Dust Collector) Note: Once the 654 Ultra-Jet Dust Collector has been in operation for several hours, a stable operating level will result. Sudden changes in operation can usually be traced to a malfunction.
Page 54
Closing the vent increases the suction. For normal concrete surfaces, Blastrac does not recommend using more than the 50 feet of exhaust hose supplied with the blast system. Adding additional hose can...
Page 55
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Troubleshooting 10.3 Continued pulled from the blast unit and deposited into the dustpan. This is particularly true when using small sizes of abrasive such as S - 170 and S - 230. When using the 654 Dust Collector with the 1-15DMKIII or 1-15DSMKIII, the vacuum adjustment gate should be fully closed for maximum suction.
Page 57
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Troubleshooting 11.1 Electrical Troubleshooting Note: All operators and maintenance personnel should read and understand the entire Operating Instructions Manual before attempting to operate or maintain this machine. Pay close attention to all safety instructions, dangers, warnings and cautions.
Page 58
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Troubleshooting 11.1 Continued combination controller should be examined and replaced if damaged. burnout of the current-element of an overload relay occurs, the complete overload relay must be replaced. ONLY THEN reset by turning “off” then back “on”.
Page 59
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Troubleshooting 11.2 Continued parts and other components of the combination controller should be examined and replaced if damaged. If burnout of the current-element of an overload relay occurs, the complete overload relay must be replaced. ONLY THEN, reset by turning “off”, then back “on”.
Page 60
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Troubleshooting 11.3 Cont’d Lock out power supply at the source (generator, disconnect switch, distribution panel, etc.), open panel door and check fuse on DC Drive in control panel. Check drive chain for binds.
Page 61
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Specifications Section 12 12.1 Specifications – Dust Collector 12.2 Specifications – Blast Unit 12.3 Site and Equipment Electrical Requirements...
Page 64
Table 7: Blast Unit Motor Data Motor Horsepower FLA @ 208 FLA @ 230 FLA @480 DC Gearmotor 1/4 HP 3.5* 3.5* 3.5* 1-10DMKIII Blast 10.0 HP 28.5 25.8 12.9 1-10DSMKIII Blast 15.0 HP 37.6 34.0 17.0 1-15DMKIII Blast 15.0 HP 37.6...
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Conversion 13.1 Electrical Conversion Note: This section is only applicable to dual voltage units and does not apply to single voltage machines. The control systems for the 6-54 Dust Collector and family of blast units including the 1- 10DMKIII, 1-10DSMKIII, 1-15DMKIII and 1-15DSMKIII were designed to safely operate in the range of 3 phase, 60 Hertz voltages typically available in the United States (208, 230, 460 and 480).
Page 67
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Conversion 13.1 Continued • High Voltage - If the supply voltage is a nominal 460 to 480 volt, the measured voltage should not be less than 414 volts nor more than 528 volts. If the measured voltage falls outside these parameters, it must be corrected before proceeding.
Page 68
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Electrical Conversion 13.1 Continued 3. Observe the pilot lights indicating “Proper Rotation” (Green) and “Improper Rotation” (Red). • If the red “Improper Rotation” comes on, two conditions may exist. a. A “single-phase” condition may exist. Measure voltage from each phase to ground.
Page 69
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Section 14 14.1 Spare Parts 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII...
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts 14.1 Spare parts Blast wheel unit Item 1-10D 1-15D Description Qty. Part No. Part No. B21620 Bearing unit with flange (Item 1-4) B21629 4892950 Bearing unit B21624 4959430 Bearing unit flange B20295 4959380 Felt seal B21625 4959370...
Page 71
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Liners Item 1-10 1-15 Description Qty. Part No. Part No. B20325 4990910 Top liner B20398 4899470 Left liner B20399 4899480 Right liner 9722750 4900450 Plenum side liner 4900440 4990930 Plenum top liner 9695720 4990920 Plenum bottom liner Liner screw M10 x 35 (used on 1-10 only, the screw on the...
Page 72
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Traction drive – 1-10D Item Part no. Description Qty. 9801600 Drive wheel bracket 9701980 Lifting fork E00967 Steering lever 970132-1 Drive motor bracket 4835160 Drive motor 9801140 Traction wheel yokeshaft 4900790 Traction wheel 9753460 Drive shaft 2055710...
Page 76
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Separator 1-10 1-15 Item Description Qty. Part No. Part No. B20537 6762370 Separator 9800120 9800120 Deflector 9701170 6762770 Separator tray 9704520 Separator tray lock 9703850 Part of 6762540 Separator handle 9800110 6762540 Separator cover Fig.
Page 77
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Blast housing 1-10 1-15 Item Description Qty. Part No. Part No. 975357-1 6761700 Blast housing 9796440 6762610 Blast wheel cover plate 6940730 4146990 Control cage clamp B20453 Blast housing cover seal B20433 4990880 Blast housing cover E00968 4899450...
Page 78
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Magnetic valve unit 1-10 1-15 Item Description Qty. Part No. Part No. B20443 4937000 Feed spout B20444 6800200 Magnetic valve assembly B20446 P000019 Valve lever B20519 P000735 Abrasive control lever B20520 P000737 Abrasive control cable B20521 4917260 Pivot for abrasive control cable...
Page 79
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Blast head 1-10 1-15 Item Description Qty. Part No. Part No. 9700300 4990970 Front magnet 4900470 4899450 Side magnet B20410 Front brush (used on 1-10 only) B20411 Side brush right (used on 1-10 only) B20423 Side brush left (used on 1-10 only) 6796740...
Page 80
(3.65PD w/bushing 1-15) 4932630 6997060 Blast motor belt 980008-1 6769980 Motor bracket 9701710 P000695 Keep plate 4915870 Blast motor – 1-10DMKIII 6976380 Blast motor - 1-10DSMKIII 6976390 Blast motor - 1-15DSMKIII B21629 4892950 Bearing unit 9701990 6762470 Idler wheel bracket...
Page 82
Operating Instructions 1-10D/1-10DSMKIII & 1-15D/1-15DSMKIII Spare Parts Rebound plenum Item 1-10 1-15 Description Qty. Part No. Part No. 9800090 6760380 Rebound plenum B20319 See note Shaft cover 2621-229 See note Sleeve-bearing bush B20315 See note Lifting plate B20318 See note Seal retainer 960855-2 See note...
Need help?
Do you have a question about the 1-10DMKIII and is the answer not in the manual?
Questions and answers