Blastrac 1-8DECMKI User manual

MODEL
1-8DECMKI
Shot Blasting System
WALK BEHIND MANUAL PUSH
Trust the Original Surface Preparation Experts
800.256.3440 blastrac.com

Operating Instructions 1-8DEC 230V
Safety Instructions
Section 1
1.1 Safety Instructions
1.2 Safety Mechanical
1.3 Safety Electrical
1.4 Safety Ventilation
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Operating Instructions 1-8DEC 230V
Safety Instructions
1.1 Safety Instructions
Note: All operators and maintenance personnel should read this
section and the safety instructions below before operating or
maintaining this equipment.
This Blastrac Operator’s Manual has been specifically prepared for operating and
maintenance personnel working with the Model 1-8DEC 208/230V shot-blasting
system. The information in this manual is intended to provide an understanding of the
equipment for safe operation and proper maintenance.
Safety Instructions
All operating and maintenance personnel must observe all warnings and precautions
that are listed in this manual for the Model 1-8DEC 208/230V. All safety and warning
labels posted on the machine must be followed as well as the safety program
instituted by your individual management.
This Blastrac equipment has been manufactured for specific floor preparation
applications. The engineering design of this airless media blast machine incorporates
several basic elements. These include the airless media blast wheel, media recycling
system and dust collection system. As a result of many years of operating and
engineering experience, the features of these machines when used with the proper
operating and maintenance procedures enable them to operate in a safe, efficient and
trouble-free manner.
A thorough understanding of your Blastrac machine will help ensure that the machine
can be operated efficiently and safely. No instructions, written or verbal, can be
effective without the use of sound judgment and good work practices in the operation
and maintenance of the equipment. Listed below are the practices that should always
be observed.
CAUTION
Always keep the abrasive valve control lever in the off/closed position except when the
machine is actually blast cleaning. Whenever an irregular, unusual or hazardous
performance of the machine occurs, immediately close the abrasive control valve,
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Operating Instructions 1-8DEC 230V
Safety Instructions
1.1 Continued
release the handle mounted traverse control lever to deactivate the travel limit switch
and shut off the blast wheel motor. An emergency stop switch is also provided on the
front of the control panel that may also be used in the event of an emergency situation.
Before actual shotblasting can begin, the operator should be certain that the machine
can clear all obstructions in the work area. 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.
All personnel in the immediate work area must wear safety glasses with side shields
whenever the machine is blasting. Protective clothing is also recommended. Long
sleeve shirts and safety shoes should be worn and loose clothing should be avoided.
The abrasive used in the machine impacts the work surface at high velocity. Any
leakage during normal operation can sting personnel in the surrounding area. The
blast head must be sealed to the work surface during operation to prevent
abrasive leakage.
1.2 Safety 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.
Assure every power source that can produce mechanical movement has
been deactivated and locked in the off position.
Assure all potential energy sources have been minimized. (Example: Move
the machine to level ground before performing any maintenance so machine
cannot move by gravitational force.)
Assure loose or freely moveable parts of the machine have been secured
against accidental movement.
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Operating Instructions 1-8DEC 230V
Safety Instructions
1.2 Continued
2. All drive guards must be kept in place and in good condition except during
maintenance or when repair work is being performed. Once maintenance or repair
work is complete, be sure all guards are securely remounted.
3. Safety glasses with side shields should always be worn when working with or near
equipment in use. Gloves, when applicable, can be worn for added protection.
4. Loose fitting clothing and gloves should not be worn when working near belts,
chains, sprockets, shafts and other moveable components.
5. The blast machine and all areas around the machine should be kept clean. Loose
media in particular can become hazardous for foot traffic. All abrasive leaks should
be repaired immediately to help keep the work area free of loose abrasive.
6. Any condition(s) that may result in additional damage to the equipment or
cause injury to nearby personnel should be repaired immediately.
7. Do not attempt to make adjustments to the feed spout or any control cage
components while the machine is in motion or the blast wheel is operating.
All adjustments must be made when the machine is stationary, the blast wheel
is completely stopped and power has been disconnected.
8. Obey all safety and danger signs posted on the machine and all information
posted where the machine is being operated.
9. Do not operate 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 machinery.
Always drain unused abrasive from the machine and empty the dust collector
hopper before transporting the equipment.
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1.3 Safety Electrical
1. CAUTION - Line terminals may be alive when main switch is in “OFF” position.
Disconnect all power before opening enclosure doors.
2. WARNING - DO NOT operate the equipment with the electrical panel door(s) open.
3. WARNING - The opening of any of the branch circuit protective devices may
be an indication that a fault current has been interrupted. To ensure
continued protection against fire or electric shock, current carrying 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.
4. Some overload devices in the control panel have an adjustable feature. Assure
these settings comply with settings provided for each device in the electrical
schematics.
5. Never bypass overcurrent devices provided in this equipment. Never use oversized
fuses or bypass any fuses to operate the machinery. Always refer to the electrical
drawings provided for the individual machines for proper size and type of
overcurrent protection and fuses.
6. When replacing electrical components, care should be taken to use the exact
component that was originally supplied with the machine. These parts are listed in
the electrical section of this manual. The electrical components in these systems
have been coordinated for optimum protection of personnel and equipment –DO
NOT SUBSTITUTE ANY OF THESE COMPONENTS.
7. Never connect or disconnect power cables with voltage present or while under load.
8. Disconnect all power connections and observe lock out / tag out procedures
before attempting maintenance or repair of any electrical component.
9. Avoid all contact with rotating motor parts, drives or driven components.
10.Before energizing the equipment, check the condition of all power cables. All
cabling should be checked for cuts and worn condition prior to connection to the
power source.
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Operating Instructions 1-8DEC 230V
Safety Instructions
1.3 Continued
11.Cable strain relief devices are provided for all power cabling. Assure that these
strain relief devices are secured to the frame of the equipment with the hardware
provided prior to energizing the equipment.
12.While safeguards have been provided in this equipment to protect operating
personnel and equipment, ALWAYS CHECK that the proper power source is
connected (voltage, frequency and phase). Check the motors for proper rotation
once the power source has been verified. Sustained improper motor rotation can
damage machine components.
Your Blastrac Blast Unit can be operated on 208/230 volt, single phase, 60-Hertz power
ONLY. Do not attempt to operate this equipment on 50-Hertz power. A 50-Hertz blast
unit is available by contacting Blastrac.
1.4 Safety Ventilation
All abrasive blast equipment must be properly ventilated to be environmentally effective.
This benefits the operator, helps maintain efficiency and minimizes wear.
With all types of dust collectors, keep the filters as clean as possible and dispose of the
dust regularly and safely. Follow all environmental regulations when disposing of the
dust. Many types of dust have chemical and physical properties that can cause fire or
explosion. These hazards are minimized when the dust is removed on a regular basis
as recommended.
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Operating Instructions 1-8DEC 230V
Operator Responsibilities
Section 2
2.1 Operator Responsibilities
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Operating Instructions 1-8DEC 230V
Operator Responsibilities
2.1 Operator Responsibilities
1. The operator shall provide site electrical power and observe operation ampere
maximums according to the following chart.
Site Power Requirements and Blast Motor Maximum Blast Amps
Parameter
1-8DEC 208/230V
Minimum Ampere Circuit @ 208/230V
20 AMP
Maximum Ampere Circuit @ 208/230V
17 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.
4. The operator shall be responsible for the observance of all safety precautions
expressed in this manual.
5. The operator shall perform all maintenance and basic repair functions as stated and
described in this manual.
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
Metric Wrench Set
U. S. Wrench Set
Utility Knife
Metric Hex Key Set
5/16” Allen Wrench
Magnetic Broom
Buckets
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Operating Instructions 1-8DEC 230V
Description and Function
Section 3
3.1 Blast Unit –General
3.2 Blast Unit –Abrasive Cleaning Head
3.3 Blast Unit –Abrasive Control Valve
3.4 Blast Unit –Rebound Chamber (Plenum)
3.5 Blast Unit –Deflector Plate / Hopper
3.6 Blast Unit –Abrasive Seals
3.7 Blast Unit –Chassis
3.8 Blast Unit –Electrical Control Panel
3.9 Dust Collector –General
3.10 Dust Collector –Filter Chamber
3.11 Dust Collector –Control
3.12 Dust Collector –Ventilation System
3.13 Cleaning Media (Abrasive)
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Operating Instructions 1-8DEC 230V
Description and Function
3.1 Blast Unit –General
The Blastrac equipment series described herein includes the 1-8DEC 208/230V Blast
Unit. This model is used in conjunction with the Turbo Vacuum Dust Collector. Each
combination comprises a horizontal surface preparation, closed cycle, shotblasting
system. The blast unit directs high velocity, metallic abrasive toward the work surface.
The impact of each individual particle causes the surface to fracture and become loose.
The abrasive and the loose surface particles are then directed upward due to the force
of the impact and a strong airflow created by the dust collector. The mixture of shot and
contaminants enters the rebound plenum and continues its upward movement until
directed into a specially designed chamber called the separator. Inside this chamber,
an air wash cleans the abrasive and allows the contaminants to be extracted back to
the dust collector. The clean abrasive is then gravity fed to the blast wheel and the
process repeats. The blast unit is manually propelled and the BDC-1216 Vacuum Dust
Collector must always be used. The blast units consist of the following elements:
Abrasive Cleaning Head
Abrasive Control Valve
Rebound Chamber
Deflector Plate / Hopper
Abrasive Seals
Chassis
Operator Controls
Dust Collector
Filter Chamber
Dust Collector Control
Ventilation System
Cleaning Media (Abrasive)
3.2 Blast Unit –Abrasive Cleaning Head
Refer to Figure Number 2
The center of the patented abrasive cleaning head is the power driven, four bladed, six
inch blast wheel that throws abrasive towards the surface being cleaned. This center
fed centrifugal blast wheel propels the abrasive by centrifugal force at a speed of more
than 200 mph. 10

Operating Instructions 1-8DEC 230V
Description and Function
3.2 Continued
This blast wheel is enclosed in an abrasion resistant housing that is also lined with
abrasion resistant liners. These liners are located in areas where the most wear is
present. The operator can change them periodically to protect the housing. A 3
horsepower, 3600-rpm electric motor, drive the blast wheel. The motor is then
connected to a set of belts and sheaves that are in turn connected to a bearing unit.
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. The control cage determines where the abrasive is
introduced onto the rotating blades of the wheel which in turn determines where the
abrasive is being “aimed”. The setting of the control cage is very important when
setting up the “blast pattern” covered in Section 5.
An analog ammeter provides readout of the current of electric motor that drives the
blast wheel. This provides a direct indication of how much abrasive is being delivered
to the wheel. This reading should not exceed the full load amperage of the motor,
which is 17 amps at 208/230 volts.
3.3 Abrasive Control Valve
Refer to Figure Number 3
The abrasive control valve regulates the amount of abrasive delivered to the blast
wheel. The main component of this device is a butterfly valve surrounded by a ring of
magnets, which, when closed, seals off the abrasive flow. A slight gap exists between
the disk on the butterfly assembly and the inner wall of the valve. When the disk is
horizontal, the magnets provide a seal that closes the gap with steel shot and stops the
flow of abrasive. The valve is manually operated with the actuator below the handle.
Do not allow this valve to open so far that the ammeter reading exceeds the full load
amperage of the motor. (17.0 Amp @ 208/230 VAC) An adjustable stop is
incorporated on the valve actuator at the handle, which allows for this adjustment.
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Operating Instructions 1-8DEC 230V
Description and Function
3.4 Rebound Chamber (Plenum)
Once the abrasive has impacted the work surface, the shot is directed into the rebound
plenum. This curved portion of the machine absorbs a large percentage of the force
exerted by the high velocity abrasive and helps dissipate the heat generated by the
blast process. Once the abrasive and contaminant mixture reaches the top of the
rebound plenum, it enters the separator.
3.5 Deflector Plate / Hopper
Refer to Figure Number 4
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. The contaminated
abrasive then falls through a curtain of high velocity clean air, which physically
separates the heavy abrasive and the lighter contaminants. The air wash pulls the
contaminants through the separator towards the exhaust and eventually to the dust
collector. The clean abrasive falls to the bottom of the separator, then into a hopper
where it can be reused.
3.6 Abrasive Seals
Refer to Figure Number 5
Magnetic abrasive seals are present on all sides of the rectangular opening at the
bottom of the blast housing. These magnets are charged with a load of abrasive and
draw any loose abrasive onto their surface, thus providing a “seal” to help contain the
high impact abrasive from the surface being cleaned. The front and back have a brush
attached. This brush drags across the work surface and allows clean air to be drawn
inside the machine for cooling and to assist in the reclamation process.
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Operating Instructions 1-8DEC 230V
Description and Function
3.7 Chassis
All components on the blast unit are mounted on a hand-propelled unit.
The operator’s handle can be pushed down to allow the operator to lift the blast seal
over small obstructions. Once the machine is raised in this manner, gravity will force it
down once the obstruction has been cleared.
3.8 Electrical Control Panel
This panel was designed to safely operate in the range of 208/230 Volt, single phase,
60 Hertz power typically available in the U.S.
The control panel on the blast unit is provided with the following controls, instruments
and components used to operate, monitor and safeguard the operator and the unit.
1. Ammeter –Provides readout of how much current the wheel motor is drawing. This
allows the operator to monitor and control abrasive flow.
2. Blast Wheel Start / Stop / Run Switch - Allows operator to start or stop the blast
wheel.
3. Abrasive Control Valve Throttle - Used to open or close abrasive valve that controls
the flow of abrasive. (Located on the Handle)
4. Fuseless Motor and Circuit Protection –This control system was designed to comply
with the National Electric Code as a “multi-motor and other loads” branch circuit.
5. Pilot Lamp –This lamp indicates when power is available to the control panel.
3.9 Dust Collector –General
The 1-8DEC 208/230V must not be used for blast cleaning unless attached to a
proper air exhaust hose and dust collector.
The BDC-1216 dust collector is normally attached to the 1-8DEC 208/230V with 25 feet
of 2-1/4 inch diameter flexible exhaust hose. The BDC-1216 dust collector is mounted
on casters for easy mobility. In operation, the 1-8DEC 208/230V cleans parallel to the
dust collector. 13

Operating Instructions 1-8DEC 230V
Description and Function
3.10 Filter Chamber
The central part of the BDC-1216 Vacuum is the filter chamber. Dust laden air enters
the chamber from the blast machine through the exhaust hose and into the vent hose
connection located at the top of the separator lid. The dirty air passes through a
vertically mounted filter cartridge. Dust is captured on the surface of these filters
allowing clean air to pass to the clean air portion of the dust collector where it exhausts
to the open atmosphere.
3.11 Control
The operator control (on/off) for the BDC-1216 Vacuum is located on top of the motor
cover.
3.12 Ventilation System
A controlled flow of air must pass through the blast unit and the dust collector during
normal operation for the reasons listed below:
Cools blast machine components.
Helps remove residual abrasive and dust from work surface.
Collects and separates dust and contaminants from recycled abrasive.
Transports dust and contaminants to dust collector.
Ventilation air must follow a designed path through the machine(s). Any irregularities in
the path can affect the performance of the system. The air sequence follows:
1. Air enters the area around the magnetic seals of the blast unit at a high velocity and
helps sweep residual abrasive and dust from the work surface.
2. This air traverses up the rebound plenum and into the separator. The air movement
up the rebound plenum helps keep the abrasive and the chamber walls cool.
3. Air enters the abrasive hopper and selectively conveys unwanted fine particles
upward toward the exhaust port on the hopper. (See figure number 4.) The hopper
must be properly seated and secure. 14

Operating Instructions 1-8DEC 230V
Description and Function
3.12 Continued
4. The dust-laden air from the air wash is directed through the separator and into the
flexible hose. The air moves through the flexible hose to the dust collector with
sufficient velocity to carry the dust and fine particles.
5. Air enters the dust collector, passes through the filter cartridge and exhausts out of
the machine. Dust emitted from the dust collector port is an indication of a loose or
damaged filter cartridge. Replacement of the faulty filter cartridge or tightening the
wing nut holding the cartridge should be performed immediately.
The ventilation system should be monitored on a regular basis. Bad or improper
ventilation can lead to poor component life and premature wear on a number of
ventilation related items on the equipment. Some of the more important areas to
monitor, relative to the ventilation system, are:
The skirts around the blast housing should be kept in good repair.
The seals around the separator lid should be checked regularly.
The hose connections to the blast unit and the dust collector should be tight
and held in place with metal clamps.
The hose should be kept in good repair. Flattened spots, holes and wear
spots should be corrected immediately. Replace hose if necessary.
Elastomer seals on the dust collector must be maintained in good condition.
Any ventilation irregularities can have an adverse effect on the overall performance and
efficiency of the system. Improper ventilation can cause poor abrasive cleaning which
in turn increases blast wheel and liner wear. An important fact that is often ignored or
misunderstood is:
The steel abrasive causes minimum wear on the internal blast components. The
dust and contaminants are the principal cause of component wear. A well-
maintained ventilation system can minimize abrasive contamination which helps
reduce operating costs and increases the overall efficiency of the shotblasting
system.
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Operating Instructions 1-8DEC 230V
Description and Function
3.13 Cleaning Media (Abrasive)
Blastrac provides a variety of special sized, high quality abrasive for Blastrac shot
cleaning systems. This steel abrasive is made of high quality martensitic steel to
provide long operating life and minimal abrasive breakdown.
The selection of proper abrasive is very important to the performance of the Blastrac
shot cleaning system. Your Blastrac representative can help with the proper selection
of abrasive for your particular application.
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