Blastrac 1-9 DEZ User manual

MODEL
1-9 DEZ
8-17-05

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. Therefore, it is necessary
that all personnel responsible for the operation and maintenance of the machine
read the manual thoroughly. By following the instructions in this manual, this
system can be easily and effectively operated, serviced and maintained by
personnel assisted by a brief period of familiarization and training from a Blastrac
technician.
Before attempting to operate, service, or maintain the machine, the personnel
should thoroughly familiarize themselves with the physical makeup of the
machine, be familiar with the major systems of the machine, and have an
understanding of its operation.
The operating and maintenance personnel must obey all the warnings and safety
precautions posted on the side of the machine and stated throughout this
manual. Serious injury to personnel or severe damage to the equipment may
result if the warnings and precautions are not followed, or through careless
handling of this equipment.
Initial operation and maintenance must be done cautiously. Extreme care should
be taken when activating any control devices until the response of the machine
and its various components are clearly understood.
If you have any questions or problems in regard to the operation or capabilities of
this Blastrac machine, please contact:
Blastrac
6215 Aluma Valley Drive
Oklahoma City, OK 73121
405/478-3440
800/256-3440
or your nearest Service Center.

INTRODUCTION
This manual has been prepared to assist the operator and maintenance
personnel in understanding the machine so that it may be operated in the safest
and most efficient manner and maintained in the best condition. Therefore, it is
necessary that all personnel responsible for the operation and maintenance of
the machine read and understand the manual.
Before attempting to operate service or maintain the machine, the personnel
should thoroughly familiarize themselves with the physical make-up of the
machine. They should be familiar with the major components of the machine and
have a general understanding of overall operations.
The operating and maintenance personnel must obey all the warnings and safety
precautions posted on the machine and stated throughout this manual. Serious
injury to personnel or severe damage to the equipment may result if the warnings
and precautions are not followed.
Warranty card must be filled out and mailed in to facilitate notification of any
changes that occur after this manual is printed. We will send you manual
revisions that should be inserted in the manual in accordance with instructions
that will be forwarded with them.
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.

i

Operating Instructions 1-9DEZ
Table of Contents
Page Number
Safety Precautions 1
1.1 Safety Instructions 2
1.2 Mechanical 3
1.3 Ventilation 5
Operator Responsibilities 6
2.1 Operator Responsibilities 7
Description and Function 8
3.1 Blast Unit – General 9
Figure 3.1.1 10
3.2 Blast Unit – Abrasive Cleaning Head 11
3.3 Blast Unit – Abrasive Control Valve 11
3.4 Blast Unit – Rebound Chamber (Plenum) 12
3.5 Blast Unit – Deflector Plate / Hopper 12
3.6 Blast Unit – Abrasive Seals 12
3.7 Blast Unit – Chassis 13
3.8 Cleaning Media (Abrasive) 13
Figure 3.1.2 14
Figure 3.1.3 15
Figure 3.1.4 16
Start-Up Procedures and Precautions 17
4.1 Start-Up Procedures 18
4.2 Blast Cleaning 19
4.3 Shut Down 20
Setting the Correct Blast Pattern 21
5.1 Setting the Correct Blast Pattern 22
Figure A 22
Figure B 23
Figure C 23
Edging Mode 24
6.1 Changing to the Edging Mode 25
Figure 6.1.1 26

Operating Instructions 1-9DEZ
Table of Contents
Equipment Calibration 27
7.1 Equipment Calibration 28
Wear Parts 29
8.1 Wear Parts 30
8.2 Replacing Grinder Motor 31
Figure 8.1.1 32
8.2 Maintenance Log 34
Blast Wheel Replacement 35
9.1 Blast Wheel Replacement 36
Troubleshooting 38
10.1 Troubleshooting 39
10.2 Ventilation System (4-54SP Dust Collector) 41
10.3 Vacuum Adjustment 41
Specifications 38
11.1 Blast Unit 39
Recommended Spare Parts 42
12.1 Recommended Spare Parts List 43
Reference Drawings
General Assembly 650-0011

Operating Instructions 1-9DEZ
Safety Precautions August 2005
Section 1
1.1 Safety Instructions
1.2 Safety – Mechanical
1.3 Safety - Ventilation
1

Operating Instructions 1-9DEZ
Safety Precautions August 2005
WARNING: ALL OPERATORS AND MAINTENANCE PERSONNEL SHOULD READ
AND UNDERSTAND ALL OF THE OPERATING INSTRUCTIONS PRIOR TO
OPERATING OR MAINTAINING THE 1-9DEZ.
These Blastrac® operating instructions have been specifically prepared for operating
and maintenance personnel working with the Model 1-9DEZ shot-blasting system. The
information in this manual is intended to provide an understanding of the 1-9DEZ to
minimize safety risks and maximize 1-9DEZ performance.
1.1 Safety Instructions
All operating and maintenance personnel must observe all warnings and precautions
that are listed in this manual for the Model 1-9DEZ. All safety and warning labels
posted on the 1-9DEZ and the instructions included in these operating instructions must
be followed.
This Blastrac®1-9DEZ has been manufactured for specific floor preparation
applications. The engineering design of this airless media blast machine incorporates
several basic elements. These elements include the blast wheel, the media recycling
system and the 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 an efficient and
trouble-free manner.
A thorough understanding of your 1-9DEZ will help ensure that it can be operated
efficiently and with minimized safety risks. 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 1-9DEZ. The U.S. Department of Labor Occupational Safety &
Health Administration (OSHA) provides standards and regulations relating to the use of
portable tools on construction sites. The operator of this 1-9DEZ should be familiar with,
and understand these Regulations and Standards. These Standards and Regulations
are posted on the OSHA Website at www.osha.gov.
CAUTION: ALWAYS KEEP THE ABRASIVE VALVE CONTROL LEVER IN THE
OFF/CLOSED POSITION EXCEPT WHEN THE 1-9DEZ IS ACTUALLY BLAST
CLEANING. IMMEDIATELY CLOSE THE ABRASIVE CONTROL VALVE BY
RELEASING THE HANDLE-MOUNTED SHOT VALVE CONTROL IF YOU
EXPERIENCE ANY IRREGULAR OR HAZARDOUS SITUATIONS WHILE
OPERATING OR MAINTAINING THE 1-9DEZ. UNUSUAL SITUATIONS INCLUDE,
BUT ARE NOT LIMITED TO, LOUD NOISE AND EXCESSIVE VIBRATION.
2

Operating Instructions 1-9DEZ
Safety Precautions August 2005
1.1 Cont’d
Before actual shotblasting can begin, the operator should be certain that the 1-9DEZ will
clear all obstructions in the work area. Work areas must be dry and clean (no loose
debris) before cleaning can begin.
WARNING: LOOSE DEBRIS MAY CAUSE A CATASTROPHIC FAILURE OF THE
BLAST WHEEL RESULTING IN SERIOUS INJURY.
WARNING: KEEP ALL GUARDS IN PLACE - THE 1-9DEZ IS EQUIPPED WITH
GUARDS OR COVERS FOR PARTS THAT MAY BE HAZARDOUS. IF ANY
GUARDS ARE REMOVED FOR MAINTENANCE, VERIFY THAT THE GUARDS
HAVE BEEN REPLACED AND ARE FUNCTIONING PRIOR TO USING THE 1-9DEZ.
REFER TO DRAWINGS 650-0011 FOR CORRECT PLACEMENT OF GUARDS,
COVERINGS AND OTHER 1-9DEZ COMPONENT PARTS.
All personnel in the immediate work area must wear safety glasses with side shields
and hearing protection whenever the 1-9DEZ is blasting; protective clothing is also
recommended. Long sleeve shirts and safety shoes should be worn. The abrasive used
in the 1-9DEZ impacts the work surface at high velocity; therefore any leakage during
normal operation may sting personnel in the surrounding area. The blast head must be
sealed to the work surface during operation to prevent abrasive leakage. Loose
clothing, long hair and jewelry should not be worn when operating or maintaining the 1-
9DEZ.
1.2 Safety – Mechanical
Maintenance Mode
Maintenance mode is defined as the state or condition of the 1-9DEZ, which minimizes
mechanical and electrical hazards.
The 1-9DEZ should be put into maintenance mode prior to making adjustments or
attempting any maintenance. The steps for placing the 1-9DEZ in maintenance mode
are listed below.
1. Move 1-9DEZ to level ground.
2. Turn off main power at electrical box located on steering handle.
3. Verify all moving parts have stopped.
4. Release grinder power trigger by simultaneously pressing the grinder power
trigger and unlock button located on the back of the grinder.
5. Utilize Lock-Out/Tag-Out procedures on main power on/off switch on the
electrical box located on the steering handle.
3

Operating Instructions 1-9DEZ
Safety Precautions August 2005
1.2 Cont’d
Most industrial and many commercial work sites will have their own Lock-Out/Tag-out
procedures. The site safety personnel should be contacted to establish the procedure to
be used. If the site has no formal Lockout/Tag out procedure the operator of this 1-
9DEZ should be prepared to implement their own procedure including training of all
operating and maintenance personnel.
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 and operating.
Safety glasses with side shields and hearing protection must always be worn when
working with or near the 1-9DEZ while in use.
Loose fitting clothing should not be worn when working with the 1-9DEZ. Gloves can be
worn for added protection, however loose fitting gloves could be dangerous.
The 1-9DEZ and all areas around the 1-9DEZ should be kept clean. Loose media in
particular can become hazardous for foot traffic. All abrasive leaks should be stopped
immediately to help keep the work area free of spilled abrasive.
Any condition(s) that may result in damage to the 1-9DEZ or cause injury to the
operator and/or other personnel should be repaired immediately.
Do not attempt to make adjustments to the feed spout or any control cage components
while the 1-9DEZ is in motion or the blast wheel is operating. All adjustments must be
made after the 1-9DEZ as been put in Maintenance Mode (See page 3).
Obey all safety and danger signs posted on the 1-9DEZ, read and understand the
Operating Instructions thoroughly, and follow all information posted where the 1-9DEZ is
being operated.
CAUTION: ALL SAFETY AND WARNING STICKERS MUST BE KEPT IN GOOD,
READABLE CONDITION. SEE DRAWING NUMBER 650-XXXX FOR STICKER
DESCRIPTIONS AND LOCATIONS.
Do not operate the 1-9DEZ in the rain or when heavy moisture is present. Do not
expose the abrasive supply to any type of moisture. Removal of sticky and/or rubber
surfaces should be avoided when using the Blastrac®1-9DEZ. Always drain unused
abrasive from the 1-9DEZ and empty the dust collector hopper before transporting the
1-9DEZ.
4

Operating Instructions 1-9DEZ
Safety Precautions August 2005
1.3 Ventilation
The 1-9DEZ will not operate correctly without a dust collector.
The dust collector aids in the recovery of the abrasive and removes potentially
hazardous dust from the air stream. If the machine is leaving shot on the ground or
emitting dust, make sure your dust collector is operating correctly. Moreover, the dust
collector helps maintain cleaning efficiency and minimizes the wear of the 1-9DEZ
component parts.
All abrasive blast equipment must be properly ventilated to be environmentally effective.
This benefits the operator, helps maintain efficiency and minimizes wear.
Keep the dust collector 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.
Be sure to obtain any MSDS that may pertain to the specific use of the 1-9DEZ. Always
be aware that the dust generated may require the operator to wear the appropriate
breathing apparatus according to the recommendations of the MSDS.
WARNING: WEAR APPROPRIATE RESPIRATORY PROTECTION WHEN USING
OR SERVICING THE MACHINE. BREATHABLE (RESPIRABLE) SILICA DUST MAY
BE GENERATED BY USE OF THIS PRODUCT AND CAN CAUSE SEVERE AND
PERMANENT LUNG DAMAGE, CANCER, AND OTHER SERIOUS DISEASES. DO
NOT BREATHE THE DUST. DO NOT RELY ON YOUR SIGHT OR SMELL TO
DETERMINE IF SILICA DUST IS IN THE AIR. SILICA DUST MAY BE IN THE AIR
WITHOUT A VISIBLE DUST CLOUD. IF AIR MONITORING EQUIPMENT FOR
SILICA IS NOT PROVIDED BY YOUR EMPLOYER AT YOUR WORKSITE, CONSULT
YOUR EMPLOYER AND OSHA REGARDING THE APPROPRIATE RESPIRATORY
PROTECTION OR PERMISSIBLE ALTERNATE PROTECTION METHODS SUCH AS
AIR MONITORING AND WARNING EQUIPMENT.
5

Operating Instructions 1-9DEZ
Owner/Operator Responsibilities August 2005
Section 2
2.1 Owner/Operator Responsibilities
6

Operating Instructions 1-9DEZ
Owner/Operator Responsibilities August 2005
2.1 Owner/Operator Responsibilities
1. The owner/operator is responsible for the observance of all safety precautions
expressed in this manual.
2. The owner/operator should be trained by a Blastrac Technician for the operation and
maintenance of Blastrac equipment.
3. The owner/operator should provide the necessary blasting media in accordance with the
recommendations of a Blastrac Technician so that the 1-9DEZ will operate at its
maximum efficiency.
4. The owner/operator must perform all maintenance and basic repair functions as stated
and described in this manual.
5. The owner/operator should maintain an inventory of wear parts as outlined in this
manual.
6. The owner/operator must dispose of all dust collector refuse according to the appropriate
local, state and federal guidelines.
7. The owner/operator should provide the following minimum tools and accessories:
Hammer Screwdrivers
Metric Wrench Set Imperial Wrench Set
Utility Knife Metric Hex Key Set
5/16” Allen Wrench Magnetic Broom
Buckets Imperial Hex Key Set
7

Operating Instructions 1-9DEZ
Description and Function August 2005
8
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 Cleaning Media (Abrasive)

Operating Instructions 1-9DEZ
Description and Function August 2005
9
3.1 Blast Unit – General
The Blastrac®equipment series described herein includes the 1-9DEZ Blast Unit. This
model is used in conjunction with the Turbo II Dust Collector (Please refer to section 1.3
ventilation). 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 consists of the
following elements: See figure 3.1.1 on page 9.
•Abrasive Cleaning Head
•Abrasive Control Valve
•Rebound Chamber
•Deflector Plate / Hopper
•Abrasive Seals
•Chassis
•Ventilation System
•Cleaning Media (Abrasive)

Operating Instructions 1-9DEZ
Description and Function August 2005
10
ABRASIVE CLEANING HEAD
SEE FIGURE 3.1.2 PAGE 14
DEFLECTOR PLATE - HOPPER
SEE FIGURE 3.1.4 PAGE 16
REBOUND CHAMBER (PLENUM)
SEEE FIGURE 3.1.4 PAGE 16
ANGLE GRINDER
GRINDER TRIGGER
GRINDER TIGGER
LOCK BUTTON
CHASSIS
ABRASIVE CONTROL VALVE
SEE FIGURE 3.1.3 PAGE 15
2" VACUUM PORT - CONNECT
TO TURBO VAC II (200 CFM)
STEERING HANDLE HEIGHT
ADJUSTMENT KNOB
STEERING HANDLE
ELECTRIC
CONTROL BOX
ABRASIVE CONTROL
VALVE HANDLE
STEERING HANDLE
MAGNETS
1-9DEZ General Components
(See drawing 650-0011 for a detailed parts breakdown)
FIGURE 3.1.1

Operating Instructions 1-9DEZ
Description and Function August 2005
11
3.2 Blast Unit – Abrasive Cleaning Head
This section (3.2) refers to 3.1.2 on page 14.
The center of the patented abrasive cleaning head is the four bladed, six-inch blast
wheel that accelerates the abrasive towards the surface being cleaned. This center fed
blast wheel propels the abrasive by centrifugal force at a speed of more than 200 mph.
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 must change them periodically to protect the housing. The blast
wheel is directly connected to an 8,000 RPM (no-load), 110V angle grinder.
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. The
impeller also acts as a timing device to ensure proper placement of abrasive on the
blade face. Abrasive that is gravity fed to the center of the wheel is pre-accelerated by
impeller 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.” Refer to Section 5 for setting the correct
blast pattern.
3.3 Blast Unit – Abrasive Control Valve
This section (3.3) refers to Figure 3.1.3 on page 15.
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
magnetic strip. A slight gap exists between the disk on the butterfly assembly and the
inner wall of the valve. When the disk is horizontal, the magnetic strip provides 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. Should the abrasive valve need to be
replaced, the lever arm should be oriented at approximately 45 degrees when the valve
is closed (see figure 3.1.3) after inserting the new valve.

Operating Instructions 1-9DEZ
Description and Function August 2005
12
3.4 Blast Unit – Rebound Chamber (Plenum)
Once the abrasive has impacted the work surface, the shot is directed into the rebound
plenum. This curved portion of the plenum absorbs a large percentage of the force
exerted by the high velocity abrasive and helps dissipate the heat generated by the
blast process.
3.5 Blast Unit – Deflector Plate / Hopper
This section (3.5) refers to 3.1.4 on page 16.
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 recycled.
3.6 Blast Unit – Abrasive Seals
This section (3.6) refers to Figure 6.1.1 on page 26.
Magnetic abrasive seals are present on all sides of the rectangular opening at the
bottom of the blast housing. These magnets should be charged with a load of abrasive
before the blasting process begins. During the blasting process, they will attract any
loose abrasive onto their surface, thus providing a “seal” to help contain the high impact
abrasive from escaping the blast chamber. The leading and trailing edges of the blast
chamber are equipped with additional brush seals mounted on the outside of the
magnetic seals. The brush seals drag across the work surface allowing clean air to be
drawn inside the 1-9DEZ. The air draw aids in the cooling and the recycling process.

Operating Instructions 1-9DEZ
Description and Function August 2005
13
3.7 Blast Unit – Chassis
All components on the blast unit are mounted on a mobile transporter. This transporter,
consists of a two-wheeled rear chassis with an additional two-wheeled front caster kit
for added stability.
The adjustable operator’s handle connected to the chassis and may be pushed down to
allow the operator to lift the blast seal over small obstructions. For safety reasons, we
recommend that the bottom of the front urethane seal not be lifted more than
approximately 1/8 inch from the surface being cleaned. Warning: Lifting the seal edge
beyond this may allow high velocity abrasive to escape the blast chamber (See
Section 1).
3.8 Cleaning Media (Abrasive)
Blastrac provides a variety of specially sized, high quality abrasive for Blastrac shot
blasting systems. This steel abrasive is made of high quality martensitic steel to provide
long operating life and minimal abrasive breakdown.
The 1-9DEZ is designed to operate with abrasive in sizes S-110 through S-330. 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.
The steel abrasive causes minimum wear on the internal blast components. The dust
and contaminants are the principal causes of component wear. A well-maintained
ventilation system will minimize abrasive contamination, which helps reduce operating
costs and increases the overall efficiency of the shotblasting system.

Operating Instructions 1-9DEZ
Description and Function August 2005
14
GRINDER ADAPTER
PLATE
POLYURETHANE
SEAL
CONTROL
CAGE
FEED
SPOUT
FEEDSPOUT/
CONTROL CAGE
CLAMP
BLAST WHEEL
DRIVE HUB
ARBOR NUT
Abrasive Cleaning Head
FIGURE 3.1.2