BlastPro BP-505 User manual

BP-505
MACHINE MANUAL

Table of Contents
Applications ..........................................................................................................3
Specifications........................................................................................................3
Manufacturer.........................................................................................................3
General.................................................................................................................4
Work Site Assessment & Inspection.....................................................................4
Start-Up Procedures.............................................................................................6
Operational Safety Procedures.............................................................................7
Shut-Down Procedures.........................................................................................8
Maintenance Procedures......................................................................................8
Operating Instructions...........................................................................................9
Eletric Drive Levers.............................................................................................11
Turning-Off the Machine .....................................................................................11
Operation Adjustments & Recommendations .....................................................11
Transportation.....................................................................................................13
Inspection Timetable...........................................................................................13
Blast Wheel Blades & Impeller Replacement......................................................14
Changing the Liners............................................................................................14
Wear Parts..........................................................................................................15
Schematics.........................................................................................................16
Warranty Registration Information ......................................................................20
Warranty Registration Card ................................................................................22

BP-505 Machine Manual
© 2011 Blastpro Manufacturing Inc.®
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Applications
The shot blasting machine cleans steel & features modular construction that allows the
machine to be dismantled & fit through a 24” manhole. The BP-505 has a 20” blast
pattern, a thirty horsepower electric motor, which results in superior cleaning
performance. The BP-505 is the most powerful, the most productive, & the only
breakdown machine on the market today which features a 30 horsepower electric
motor. The BP-505 can be dismantled, fit through a 24” manhole, & reassembled by
three men in approximately 75 minutes. The BP-505 is the most advanced steel
cleaning system currently available. It is ideal for cleaning floors & roofs on oil storage
tanks. When used in conjunction with the BP 9-54 Duct Collector, the BP 505 is an
excellent choice for removing non-skid from ship decks. The mechanics of the BP-505
are fairly simple. After mechanical pre-acceleration, metallic shot is shot onto the
underlying surface at a very high rate of speed by the blast wheel. The forceful impact
of the shot onto the surface systematically removes surface contaminants, coats of
paint, sealants, & thin coatings. After hitting the surface, the shot immediately rebounds
into a recovery duct. The recovery duct then sends the shot into an air current
separator. Once here, dust & other contaminants are removed from the shot so that
only the shot & a negligible amount of dust are allowed to move into the shot storage
hopper for re-use by the blast wheel. By severely restricting the amount of dust that is
allowed to escape into the environment, the BP-505 acts to benefit both the working
staff & the air quality at the work site.
Specifications
Drive Motor
Electric
Weight
1542 lbs.
Travel Speed
2.5-95 ft./min.
Dimensions (L x W x H)
64” x 70” x 27”
Blast Type
SSPC-SP10
Surface Profile
3 Mils
Blast Motor
30 HP
Minimum Generator
75 kW
Steering
Electric
Manufacturer
Blastpro Manufacturing
6021 Melrose Lane
Oklahoma City, OK 73127
Toll free: 877-495-6464
Phone: [phone]
Fax: [phone]
Website: www.blastpromfg.com

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General
All operators & maintenance personnel should read this section carefully before operating
or maintaining this equipment. These safety instructions are not meant to represent an
all-inclusive list of instances which could occur when operating this equipment. For, as
with any piece of construction equipment, serious injury can occur if proper safety
procedures are not diligently followed. All safety & warning labels posted on the machine
must be followed as well as the safety program instituted by your company. There is no
substitute for sound judgement in the operation & maintenance of this equipment. In
cases where operating personnel have insufficient knowledge or understanding of the
English language, proper translated training must be completed before use of this
equipment can take place. This manual must be kept with the machine at all times so as
to allow the operator easy access to its vital information. The united states department of
labor’s occupational safety & health administration (OSHA) provides statutory
requirements, standards, & regulations relating to the use of portable tools on
construction sites. These statutory requirements, standards, & regulations are posted on
the osha website at www.osha.gov. The operator & maintenance personnel should
understand & follow these statutory requirements, standards, & regulations.
Work Site Assessment & Inspection
Before starting blasting operations, a site assessment must be performed. During the
site assessment verify the following:
1. Work area is flat, clean, & dry, free of debris, frost-free, & has no flammable liquids
nearby.
2. Make sure that the machine will be able to clear all obstructions. Never blast a wet
floor.
3. Never blast over bolts, nuts, screws, nails, or other debris as this may result in
significant damage to the machine & serious injury to the operator.
4. Work area is well ventilated. If work area is enclosed or partially enclosed
(warehouse, parking garage, tunnels, etc.), then gasoline can never be used as
the fuel source for the shot blasting machine. This is because carbon monoxide,
which is a byproduct all internal combustion engine, can be extremely hazardous
when allowed to accumulate in an area. An odorless, tasteless, & non-irritating
gas, carbon monoxide can quickly become lethal. As a result, vapor propane must
be used in all instances when the work area is enclosed or partially enclosed. The
work area must still be well ventilated, however, as vapor propane also releases
carbon monoxide. This means that extreme caution must still be used when using
this fuel source.
5. Each worker has a carbon monoxide monitor on their persons. These carbon
monoxide monitors should be calibrated, in working order, & should be equipped
with audible alarms that will warn workers if carbon monoxide levels become too
high. If carbon monoxide levels exceed 35 parts per million, all work must cease
immediately. This represents a potentially deadly situation which necessitates an
immediate shutdown.

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6. All operators & other personnel within the work area have received training on
proper ventilation procedures & on proper operation procedures for the engine &
for other types of equipment.
7. Floors have been thoroughly inspected. Some floor or deck surfaces may be
coated with or contaminated by dangerous materials such as:
•PCBs
•Lead
•Asbestos
•Pesticides
•Solvents
•Cleaning fluids
•And/or other harmful chemicals
The dust produced from shot blasting such surfaces can create a serious health threat
to those who inhale or come into contact with the dust. The work area must be checked
for these materials before work can begin. Blastpro manufacturing, inc. does not
warrant its equipment to be suitable for, or approved for, removing dangerous materials.
It is therefore the responsibility of the contractor to confirm the safety of the work area &
the equipment with the proper authorities. It is also the responsibility of the contractor to
warn all staff members of all the potential short-term & long-term health risks associated
with inhaling & coming into contact with dangerous materials. The contractor is
responsible for protecting all workers from being exposed to dangerous materials. Since
the shot blasting machine has not been designed to remove, clean, profile, or alter any
surface coated with or otherwise contaminated by dangerous materials, Blastpro
Manufacturing, Inc. expressly disclaims any liability for injury, illness, death, or damage
that might occur or result from such improper use.
8. Operator & any other personnel in the work area are wearing safety glasses with
side shields, dust masks, ear plugs, hard hats, steel toed work boots, long sleeved
shirts, tight fitting clothing, & gloves. It is also imperative for staff to tie back long
hair & to remove all jewelry.
9. Work area has been blocked off to pedestrians, unprotected personnel, &
untrained personnel. In the event pedestrians, unprotected personnel, or untrained
personnel enter the work area, blasting operations are to be stopped immediately.
10.Fire extinguishers are nearby. Also, take note of the location & the contact
information of fire departments close to the work site.
11.All guards & protective shields are properly installed & secured.
12.All glass & equipment, including vehicles, are protected from steel shot. This can
be done by loosely hanging a sheet of visqueen or other protective material in front
of the glass or equipment in a curtain-like fashion. The importance of protecting
glass & equipment from steel shot cannot be overemphasized.
13.Plug or cover all floor drains to prevent steel shot from falling into the drains.
14.This equipment is only to be used for commercial purposes. This equipment is only
to be operated by professional, trained, & competent operators.

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15.The operator must be aware of their surroundings & use common sense. The
operator is not to operate the equipment if he is tired, distracted, or under the
influence of drugs, alcohol, or medication that decreases awareness.
Start-Up Procedures
After performing the site assessment safety procedures listed above, bring the machine
to the work area & perform the following procedures:
•Verify that personnel are competent & that they have read & understood the safety
information in this manual. Staff must also be familiar with how to operate the
machine & with all of its components. Make certain that all personnel follow all
safety instructions & programs required by their company & by the worksite.
•Verify that all machine parts are assembled safely & correctly. It is recommended
to have original spare parts & wear parts on hand. It is imperative that the machine
receive special attention & regular maintenance in order to function properly & to
operate safely.
•Make certain that all screws & other fasteners are tight.
•Check the shot storage hopper, the feed spout, & the blast wheel parts for foreign
bodies & remove them if present.
•Check the blast wheel blades, impeller, control cage, liners, & fastening screws for
damages & wear. Wear grooves are acceptable until 75% of blade thickness has
been worn away. When blade thickness has been worn away by more than 75%,
replace all blades as a set.
•Check the front, side, & rear seal system & brush seals for excessive wear.
•Check the tightness of the hose connections & the condition of the hose to the
filter.
•Make sure the dust container of the filter unit is empty.
•Check the separator parts for wear & defects. Remove foreign bodies & dust
deposits in order to prevent the separator from being blocked.
•Check the electrical connections for dirt & foreign body deposits.
•Verify that the electrical motors are free of dirt & other contaminants.
•Check the level of shot in the storage hopper. Refill hopper if necessary.
•Verify that the main power cable & the dust hose are free of damage. Replace or
repair all damaged parts before putting the machine into operation.
•Connect the blast cleaning machine & the filter unit with the dust hose. Use hose
clamps at the connections.
•Connect the supply cable of the blast cleaning machine with filter unit. Connect the
electrical cable of the filter unit with the site supply.
•Make certain that the side seals are positioned correctly in the side seal boxes.
•Fill approximately 100 lbs. of the selected shot into the shot storage hopper of the
machine. The shot valve must be closed while doing this.
•Check that the filter dust container has been emptied.

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•Blast in a straight line. Blasting in a straight line will produce the most uniform
results. Never run over anything with the machine. Running over an extension
cord, air lines, rebar expansion joints, openings in floor, drains, etc. with the
machine can result in serious injury to the operator and/or damage to the
equipment.
•Make certain to keep hands away from all moving parts once the machine is in
operation.
•Make certain to never stand next to the blast housing while the machine is in
operation as blade failure could result in serious injury.
•Make certain that the shot hopper door is closed while the machine is in operation
as the machine throws shot which could present a serious danger if the shot
hopper door is not properly closed.
•Make certain that the blast seals of the machine are not worn out. As these seals
provide the suction that is required by the machine, they will become dislodged if
they become worn out. This will then result in shot being discharged from the
machine. It is consequently recommended that the operator make absolutely
certain that the blast seals are in good working condition before putting the BP 505
into operation.
If the shot blasting machine is operated using a generator as the power source, the
generator must be operated in accordance with the current VDE directives (this applies
to the protective earth conductor in particular) in order to ensure that all safety devices
are functioning & to eliminate possible damage to electrical components.
Operational Safety Procedures
When operating the machine, perform the following safety procedures:
•Support personnel must keep a safe distance from the machine while it is in
operation. Do not stand in front of the machine while it is in operation.
•Since the speed of the machine determines the depth of its cut, it is advised that
the operator run a test pattern. Failure to run a test pattern could result in the
machine gouging the floor.
•The blast pattern needs to be inspected by the operator at least every ten feet as
variation in concrete means that the concrete or the coated surface may be softer
in some areas than it is in others.
•Whenever the dust collector becomes full, it must be emptied. Failure to empty the
dust collector could result in the machine losing its suction to the floor. If this
happens, then all of the shot will fall out of the shot hopper.
•Never switch off or remove the exhaust & ventilation devices when the machine is
in operation.
•A second person must be present so as to pull out the machine’s plug in an
emergency. The work area must then be sealed off using a red & white safety
chain & a danger sign. Use a tool that is insulated against voltages.
•Make certain circuit breakers can handle the electrical load required by the
machine.

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•If an error occurs while the machine is in operation, it must be shut down
immediately. The cause of the error must be established immediately.
•If cables become loose or scorched, the machine must be shut down immediately.
Shut-Down Procedures
When shutting down the machine, always perform the following safety procedures:
•Shut off the shot supply by pushing down the shot valve handle.
•Advance the machine until you are sure that no deep holes are being blasted into
the surface.
•Press the push button “main blast off.” This switches off the blast wheel motor.
•Press the push button “drive off.” This switches off the drive motor.
•Press the push button “fan off.” This switches off the fan motor.
•Set the main switch on the main box at the front of the blast cleaning machine to
“off.”
•After several minutes press the push buttons “compressor off,” “fan off,” &
“pulsator off” on the filter unit.
•Set the main switch of the filter unit to “off.”
•Empty dust from the dust collector. When removing dust from dust collector,
always wear a particle mask. Concrete dust may contain particles which are
extremely hazardous. These particles should never be inhaled.
•Empty all shot from the shot hopper on the machine. Shot should never be left in
the machine after work is performed. Never move or transport the machine with
shot or dust in the shot hopper as this may result in damage to the equipment.
•After completing work, clean all stray shot from work area. Shot can be cleaned
with a magnetic broom or with a shop vacuum. Never leave stray shot in work
area as shot represents a slip & fall hazard. Stepping & falling on steel shot can
result in serious injury or even death.
Maintenance Procedures
When performing maintenance on the machine, make certain that the following safety
procedures are followed:
•Verify that the machine & the dust collector are not in operation. Attempting to
perform maintenance operations on the BP 505 or the dust collector while in
operation could lead to serious injury or death.
•Verify that the machine & the dust collector are on a level & stable surface.
•Make certain that the machine is in the Safety off position (valve is closed, blast
machine is switched off, dust collector is switched off, all drives are at a standstill,
& main plug has been pulled).
•Make certain maintenance personnel are wearing lint-free cleaning cloths.

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•If repairing the underside of the machine, then be certain to use jack stands. Never
work under equipment that is not properly blocked.
•All repairs to electrical components, including wiring, should be performed by a
licensed electrician.
•When performing electrical servicing work, make certain that all replacement
electrical components comply with the original parts & are correctly adjusted.
•All other repairs must be completed by competent, qualified personnel.
•Make certain that process materials & replaced parts are disposed of safely & in
an environmentally-appropriate manner.
•Failure to replace loose or damaged parts could cause damage to the equipment
and/or serious injury or death to the operator.
•Verify that aggressive cleaning products are not used.
•Make certain to never weld, flame cut/torch, or perform any grinding work on the
machine without written authorization from the manufacturer.
•Make certain that electrical equipment is inspected regularly.
•Verify that all screw connections that were undone during maintenance work are
retightened prior to putting the machine back into operation.
•After performing maintenance operations on the machine & dust collector, verify
that all safety labels, guards, control panels, housings, lids, seals, casters,
magnets & other parts that have been replaced are secure.
The tasks listed in the following check list must be completed before the machine can be
put into operation; completing these tasks is essential in order to increase the efficiency
& safety of the machine:
Blades
Check for excessive wear.
Blast Wheel
Check for balance & excessive wear.
Top Liner
Check for excessive wear.
Lower Liner
Check for excessive wear.
Gap
To adjust gap, see Operation Adjustments section.
Blast Wheel Bearing
Check set screws & grease
Shot Valve
Make sure shot is not leaking from shot hopper.
Filters
Make sure filters are secure & not clogged, ripped, or wet.
Tires
Check for excessive wear.
Blower Bearings
Check set screws & grease.
Dust Collector Latches
Make sure latch firmly secures door.
Operating Instructions
Before putting the machine into operation, make certain that all existing protective
housings are mounted & that the filter unit is correctly connected. To operate the machine,
follow the steps listed below:
To turn on the filter unit:

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1. Main switch of the filter unit “ON.”
2. Fan “ON.”
3. Compressor “ON.”
4. Pulsator “ON.”
5. Check the turning direction of the filter & compressor motor. The correct turning
direction is indicated by the arrow on the fan motor.
For initial operation:
1. Check that the shot valve is closed.
2. Check that the emergency shutdown switch is not activated.
3. Ensure that the electric drive levers are centered.
4. Switch the main switch of the machine to “ON.” The control lamp “Power” on the
control box lights up.
5. Press the push button “Drive ON.”
6. Press the push button “Fan ON.”
7. Press the push button “Main blast ON.” The blast wheel motor is started.
8. Observe the ammeter in order to check the power consumption of the blast wheel
motor. The motor requires a lot of power (starting current) when it is started until it
reaches its maximum speed.
9. Once the blast wheel has reached its rated speed the current drops to
approximately 10 A no-load consumption.
10.If the ammeter indicates more than the normal current value after 10 seconds,
interrupt the power supply & find the cause.
11.If the ammeter indicates high load consumption after having reached the idle-
running speed, the shot valve may be partially open or there may be another
disturbance. Find out the cause of the disturbance and, if necessary, contact
Blastpro Manufacturing, Inc.
12.To steer the machine, manipulate the electric drive levers. See Electric Drive
Levers section below for further instruction.
13.When the machine is traveling, pull the shot control lever to operate the valve.
Observe the ammeter. It may indicate the full load amperage (35 A).
14.An indication exceeding the full load value means overloading of the motor,
whereas an indication below the full load value shows that there is not enough shot
fed to the blast wheel. If necessary, then re-adjust the shot valve handle that
operates the shot vale or refill the hopper with shot.
15.After having blasted approximately 2 meters close the shot valve, stop the
machine, & check the blasted surface.
16.If the blast pattern is irregular it may be necessary to re-adjust the blast pattern or
select another travel speed for the machine. If necessary, refer to Setting the Blast
Pattern located in the Operation Adjustments & Recommendations section.
It is strongly recommended that the operator blast in straight lines. Doing so will permit
the operator to blast in parallel tracks which will consequently reduce the chance that the
dust hose & the electric cable become intertwined. Also, it is imperative to never allow
vehicles to run over the dust hose and/or the electric cable. The selection of the correct
advancing speed of the blast machine is important for a good blast result. In the case that