Blastrac 1-15DS User manual

Operating Instructions
1-15DS
MAN-1-15DS-EN

Technical data
Safety instructions
General
Transport
Initial operation
Operation
Maintenance
Electrical systems
Fault diagnosis
Spare parts
Design and specifications are subject to
change without notice - Augustus 2000
Blastrac
Utrechthaven 12
3433 PN Nieuwegein
THE NETHERLANDS
T +31(0)30 - 601 88 66
F +31(0)30 - 601 83 33
E [email protected]
I www.blastrac.com
Nieuwegein

1-15DS Operating Instructions
Technical data
Contents Chapter 1
1.1 Rating
1.2 Unit specifications
1.3 Operative range and correct usage
1.4 Stand-by power supply (generator)
1.5 Machine type designation
1.6 Advice for operators of blast cleaning machines
1

Operating Instructions 1-15DS
Technical data
1.1 Rating
Unit / designation : Blastrac blast cleaning machine
Machine type : 1-15 DS MK II
Manufacturer : Blastrac
Utrechthaven 12
NL-3433PN Nieuwegein
THE NETHERLANDS
1.2 Unit specifications
Dimensions:
1-15DS
Length 1800 mm
Width 570 mm
Height 1200 mm
Weight 500 kg
Connected loads (electrical system):
The indicated input current values correspond to the nominal current
values of the motors working under full load. These values are not
achieved under normal operating conditions.
1-15DS Power
consumption
Input
current
Blast wheel drive 15,0 kW max. 30 A
Drive motor 1,1 kW max. 2,8 A
Dust collector 5,55 kW max. 12 A
Electrical connection required : 400 V, 50 Hz, 63 A, CEE plug
2

1-15DS Operating Instructions
Technical data
Blast wheel size : 200 mm Ø
Working width : 380 mm
Drive speed : 0,5 - 29 m/min
Blast cleaning output on concrete : up to 240 m²/h
Dust hose connection : 150 mm Ø
Recommended abrasive : Media No. 2 - No. 5
Abrasive consumption : 100 g/m²
Contact Blastrac for a suitable Blastrac filter unit
1.3 Operative range and correct usage
The 1-15DS is exclusively designed to clean dry,
frost-free horizontal surfaces. The machine may not
be used for other purposes. The manufacturer will
not be liable for damage resulting from such
incorrect usage. In these cases the user assumes all
risks.
1.4 Stand-by power supply (generator)
If the 1-15DS blast cleaning machine is operated
using a generator, this 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 and to eliminate possible damage to
electrical components.
3

Operating Instructions 1-15DS
Technical data
1.5 Machine type designation
number of blast wheel
s
blast cleaning widt
h
product cod
e
1 - 15 DS
1.6 Advise for operators of blast cleaning machines
In accordance with the accident prevention regulations for blast
cleaning work (VBG 48) the operator must provide operating
instructions for blast cleaning work in a form and language that is
understandable.
The blast cleaning machine Operating Instructions are only part of
these operating instructions. Please consult the current accident
prevention regulations for the precise content.
During operation the acceptable noise level of the 1-15DS blast
cleaning machine could exceed 85 dB(A). This noise level
depends on the local circumstances. When the noise level is 85
dB(A) or more, the machine operator and persons working near
the machine must wear sound-insulating equipment.
Before operation, please make inquiries after the surfaces to be
treated in view of health hazard or carcinogenic materials. When a
different filter material is needed for the filter unit, please contact our
local Blastrac customer service department.
4

1-15DS Operating Instructions
Safety instructions
Contents Chapter 2
2.0 Warnings and symbols
2.1 Organisational measures
2.2 Personnel selection and qualification
2.3 Safety precautions applicable to different operating conditions
2.4 Special work within the scope of use of the equipment and
maintenance activities as well as repairs during operation
2.5 Definition of the Safety off position
2.6 Particular dangerous aspects of the equipment
2.7 Electrical engineering regulations
1

Operating Instructions 1-15DS
Safety instructions
2.0 Warnings and symbols
The following denominations and symbols are used in the Operating
Instructions to highlight areas of particular importance:
Symbol of operational safety.
In these Operating Instructions this symbol will be
shown next to all safety precautions that are to be
taken in order to ensure prevention to life and injury.
Follow these instructions and take special care in
these circumstances. In addition to these
instructions, the general safety precautions and
accident prevention guidelines are also to be
followed.
Particular details regarding the economical use of
the equipment.
Information, instructions and restrictions with regard
to possible risks to persons or to extensive material
damages.
2

1-15DS Operating Instructions
Safety instructions
Warning against dangerous voltages.
Indications relating to protective devices in electrical
appliances.
Indications where consultation with the
manufacturer is required.
Instructions relating to periodical checks.
Reference to important instructions contained in the
Operating Instructions.
2.1 Organisational measures
The Operating Instructions are to be kept near the location
where the machine is located and must be within reach at all
times!
In addition to the Operating Instructions general and legal regulations
regarding accident prevention and environmental protection must be
complied with and indicated!
Such duties may for example relate to the handling of hazardous
substances or to the provision and wearing of personal protection
equipment as well as compliance with traffic regulations.
3

Operating Instructions 1-15DS
Safety instructions
The Operating Instructions must be supplemented by instructions
including the duty to supervise and report relating to particular
working practices, for example work organisation, work procedures
and personnel allocation.
Personnel entrusted with working with the machine must have read
the Operating Instructions before starting work, in particular the
Safety Instructions chapter. To read these instructions during work
is too late. This particularly applies to incidental activities such as
setting up the equipment, carrying out maintenance work or training
staff to work with the machine.
From time to time the working practices of the staff are to be checked
regarding awareness of safety and hazards.
Personnel must tie back long hair and not wear loose clothing or
jewellery including rings. There is a risk of injury through getting stuck
or being drawn into moving machinery.
Use personnel protection equipment if necessary or required by
regulations! Take notice of all safety and hazard notices on the
machine!
All safety and hazard notices at or on the machine must be kept
complete and legible!
If safety-critical changes occur to the machine or its working
method, the machine must be shut down immediately! The cause of
the fault must be established immediately!
Changes, add-ons or conversions to the machine which might impair
safety must not be undertaken without the manufacturer’s
permission!
This applies in particular to the fitting and adjustment of safety
devices as well as to welding on load-bearing parts.
Spare parts must comply with the technical requirements specified
by the manufacturer. This is always guaranteed if original spare
parts are used.
Intervals for recurring checks and inspections specified in these
Operating Instructions must be complied with!
4

1-15DS Operating Instructions
Safety instructions
To perform maintenance work correctly it is imperative to be equipped
with the proper tools for the task in question.
The location and the operation of fire extinguishers must be made
known on each building site!
Take note of the facilities for reporting and fighting fires!
2.2 Personnel selection and qualification
Fundamental duties :
Work on the machine may only be undertaken by reliable personnel.
Only trained personnel may be deployed. Note the statutory
minimum age! Specify clearly the responsibilities of personnel for
operation, setting up, servicing and maintenance work!
Make sure that only authorised personnel operate or work on the
machine!
Define responsibilities of the machine operator also regarding to
traffic safety regulations and empower him to decline instructions
from third parties which are not complying with the safety
requirements!
Personnel being trained or made acquainted with the equipment may
only be deployed on the machine under constant supervision of an
experienced person!
2.3 Safety precautions applicable to different operating
conditions
Ban any method of working that impairs safety!
5

Operating Instructions 1-15DS
Safety instructions
Only operate the machine when all safety devices and related
safety equipment, e.g. detachable safety devices, emergency
stops and suction devices are present and operational!
Check the machine visually for any damage and defects at least
once a day!
In the event of operational malfunctions the machine must be shut
down immediately and secured, and the fault must be rectified!
Secure the work area around the machine in public areas
providing a safety distance of at least 2m from the machine.
Before switching on the machine make sure that no-one can be
endangered when the machine starts up!
Do not switch of or remove the exhaust and ventilation devices when
the machine is running!
All persons in the proximity of the machine must wear safety
glasses with lateral protection as well as safety shoes. The
operator is obliged to wear close-fitting protective clothing.
Use only extension cable for extending the main cable that are
sized and marked in accordance with the overall power
consumption of the machine and the valid VDE guidelines.
2.4 Special work within the scope of use of the equipment and
maintenance activities as well as repairs during operation
Mechanical servicing work:
6

1-15DS Operating Instructions
Safety instructions
Put the machine in the Safety off position as described in chapter
2.5 for any servicing work on the machine in order to prevent the
machine from being switched on accidentally.
Please follow any special safety instructions in the various chapters
on servicing the machine.
See chapter 7.1 - 7.18.
Adjustment, servicing and inspection work and time limits
specified in these Operating Instructions as well as any information
on the replacement of parts and equipment must be undertaken
and/or complied with!
These activities may only be undertaken by qualified personnel.
Do not use any aggressive cleaning materials!
Use lint-free cleaning cloths!
Always tighten any screw connections that are undone during
servicing and maintenance work!
If safety devices need to be dismantled during setting up, servicing
and repairs, these safety devices must be reinstalled and inspected
immediately after completion of the servicing and repair work.
Make sure that process materials and replaced parts are
disposed of safely and in an environmentally-friendly manner!
Electrical servicing work:
Make sure that electrical components used for replacement purposes
comply with the original parts and are correctly adjusted if necessary.
For safety notes see 2.7 Electrical engineering regulations.
2.5 Definition of the Safety off position
Definition:
The machine is in a safe condition when it cannot generate any
hazard.
7

Operating Instructions 1-15DS
Safety instructions
Putting the equipment in the Safety off position means:
;Close the magnetic valve.
;Switch of the blast machine.
;Switch off the dust collector.
;Wait for standstill of all drives.
;Pull out mains plug.
2.6 Particular dangerous aspects of the equipment
Any machine, if it is not used according the regulations, may be
hazardous for operating, setting-up and service personnel. The
operating authority is responsible for compliance with the
safety regulations during operation and maintenance of safety
devices supplied with the machine as well as the provision of
appropriate additional safety devices!
1. Blast housing outlet
Danger of injury!
Abrasive leaves housing with
high speed!
Moving parts!
Lift and cant the machine only
when it is in Safety off position.
It is not allowed to stay within
the working radius of the
machine!
8

1-15DS Operating Instructions
Safety instructions
2. Drive assembly, quick
release pin
Danger of injury!
Moving parts!
Be very careful with inserting
the quick release pin.
Only authorised personnel may
operate the machine!
3. Wheels
Danger of injury!
Moving parts!
It is not allowed to stay within
the working radius of the
machine!
2.7 Electrical engineering regulations
Work on electrical equipment or operating materials may only be
undertaken by a skilled electrician or by trained persons under
the guidance and supervision of a skilled electrician as well as
in accordance with the electrical engineering regulations.
Use only extension cable for extending the main cable that are
sized and marked in accordance with the overall power
consumption of the machine and the valid VDE guidelines.
9

Operating Instructions 1-15DS
Safety instructions
The electrical equipment for the plant must inspected regularly.
Please note in particular the specified recurring inspections
according EN60204-1.Defects such as loose connections or
scorched cables must be rectified immediately. Call a skilled
electrician or our Customer Services.
A second person must be deployed who can pull out the plug in an
emergency if work on live parts is necessary. The work area must be
sealed off using a red and white safety chain and a danger sign. Use
a tool that is insulated against voltages.
Only start work once you are familiar with the electrical engineering
regulations that apply to your area.
Only use voltage seekers that comply with the regulations when
troubleshooting. From time to time check voltage seekers to ensure
that they are operationally efficient.
10

1-15DS Operating Instructions
General
Contents Chapter 3
3.1 Operative range
3.2 Scope of supply
3.3 Description
3.4 Operating elements
3.5 Blast wheel
3.6 Separator
3.7 Drive mechanism
3.8 Abrasive sealing
3.9 Abrasive media
3.10 Care and maintenance
1

Operating Instructions 1-15DS
General
3.1 Operative range
The Blastrac blast cleaning machine 1-15DS is a downward blasting
machine with a closed abrasive circuit designed for the pre-treatment
of horizontal surfaces. The bouncing impact of metallic abrasive onto
the surface to be treated thoroughly removes surface contaminants,
coats of paint, sealants and thin coatings.
A suitable filter unit must be connected to the machine in order to
separate the dust from the abrasive. A specially designed dust
collection system ensures dust-free operation of the machine and
clean air at the workspace.
3.2 Scope of supply
Scope of supply of the machine:
Blast cleaning machine
Filter unit
Dust hose (20 m)
Operating instructions (2 x)
Maintenance box (option)
Magnetic broom (option)
2

1-15DS Operating Instructions
General
3.3 Description
Fig. 3.1
1 Control box 6 Blast wheel motor
2 Separator 7 Blast head, magnets, brush sealing
3 Filter connection 8 Dead man’s handle
4 Rebound plenum 9 Feed spout
5 Drive mechanism 10 Abrasive control lever
Like many revolutionary inventions the blast wheel method is based
on a simple principle: after mechanical pre-acceleration the abrasive
is thrown onto the surface at high speed by the blast wheel. Once the
abrasive has impacted on the surface it rebounds into a rebound
plenum. The rebound plenum deflects the abrasive into an air current
separator. Here dust and other contaminants are removed from the
abrasive so that only abrasive containing a very small amount of dust
is fed into the abrasive storage hopper for re-use by the blast wheel.
3