BURWELL 1230 Manual

OPERATING AND MAINTENANCE
INSTRUCTIONS
FOR BURWELL BLAST MACHINE
(FOR 1230 & 1532 MODELS)
AUSTRALIA’S LEADING MANUFACTURER AND DISTRIBUTOR OF SURFACE PREPARATION EQUIPMENT
PAINT APPLICATION EQUIPMENT AND ABRASIVES, EXCLUSIVE AUSTRALIAN DISTRIBUTOR FOR
CLEMCO INDUSTRIES AND AQUAMISER WATER JETTING EQUIPMENT
BURWELL TECHNOLOGIES PTY LTD A.B.N. 86 001 262 013
100% AUSTRALIAN OWNED

CONTENTS
1.0 Introduction
2.0 Safety Risk Management
2.1 Hazard Identification
2.2 Risk Assessment
3.0 Hazard and Control Measures
3.1 Prohibited and Restricted Chemicals
3.2 Asbestos
3.3 Lead
3.4 Naturally Occurring Radioactive Material
4.0 Identifying Dust Hazards
5.0 Risk and Control Measures
5.1 Administrative Controls –Exclusion Zones
6.0 Personal Protective Equipment (PPE)
6.1 Respiratory Protection
6.2 Eye Protection –Helmet
6.3 Protective Clothing
6.4 Maintenance of PPE
7.0 Method of Operation
7.1 Operating Instructions
7.2 Abrasive Flow
7.3 Air Pressure requirements
7.4 Blast Nozzle Detail
8.0 Troubleshooting
9.0 Blast Pot Schematic
9.1 Valve Diagrams and Spares Listing
9.2 Deadman Controls
9.3 Breathing Air Filter
9.4 Blast Helmets
10.0 General Consumables Listing
11.0 Specifications and Test Reports

1.0: INTRODUCTION
Abrasive blasting is the process of using compressed air or water to direct a high velocity
stream of an abrasive material to clean an object or surface, abrade, etch or profile the
condition of the surface for the application of paint or other type of coating. It is used across
a wide range of industries for many different purposes, including the removal of rust and
mill scale from metal objects.
Other uses include the frosting of glass for decorative purposes, removal of finishes from
wood, cleaning plastic parts such as dentures, electronic parts etc. and removal of latence
from concrete, cleaning brick and stone buildings, removal of heat treat scales, removal of
tool marks from finished parts and a multitude of other uses. Some other applications of
abrasive blasting include:
Surface Treatment and Preparation
Cleaning and Removal
•Strength surfaces
•Add fatigue resistance.
•Improve corrosion resistance.
•Finishing and removing imperfections
•Expose flaws for inspection.
•Etch for bonding and adhesion
•Paint and coatings
•Rust and oxidation
•Carbon deposits
•Burrs and flashing
•Excess brazing
•Sealants and adhesives
Burwell Abrasive Blast Equipment is designed and built-in accordance with all Authorities. All
pressure vessels are Crown stamped and numbered for registration by customers with the
Workcover Authority of NSW.
The equipment is manufactured and marketed to meet with ever demanding requirements
of the contractors and users. It is for this reason that Burwell reserves the right to change
design specifications without notice. The result of this is that you, the customer has purchased
the most sophisticated and updated equipment possible in its field.
2.0: SAFETY AND RISK MANAGEMENT
Due to the dangerous nature of abrasive blasting, it is important to consider the hazards and
risks associated with such a process to minimise the potential for harm. Employers must
protect workers from hazardous dust levels and toxic metals that may be generated from
both the blasting material and the underlying substrate and coatings being blasted. The
Abrasive Blasting Code of Practice (2015) provides practical guidance for persons conducting
a business or undertaking the management of health and safety risks associated with
abrasive blasting. Reference should be made to this code which provides guidance on
managing the risks of abrasive blasting by following a systematic process that involves:
•Identifying hazards
•Assessing the risks associated with these hazards.
•Implementing & Reviewing control measures

2.1: Hazard Identification
The first step in managing risks associated with abrasive blasting activities is to identify all
the hazards that have the potential to cause harm. Potential hazards may be identified in a
number of different ways including:
•Conducting a walk-through assessment of the workplace
•Observing the work and talking to workers about how work is carried out.
•Inspecting the plant and equipment that will be used during the abrasive blasting
activity.
•Reading product labels, safety data sheets and manufacturer’s instruction manuals
•Talking to manufacturers, suppliers, industry associations and health and safety
specialists
•Reviewing incident reports
Common hazards include dusts, hazardous chemicals and risks associated with the use of
plant and equipment. Examples of abrasive blasting hazards include:
•Airborne contaminants such as dust
•Hazardous chemicals, particulate matter, E.g. small particles of the substrate or
blasting medium
•Abrasive blasting plant and equipment.
•Noise
2.2: Risk Assessment
A risk assessment for abrasive blasting activities can be effective in minimising potential
harm and will assist in determining the control measures that should be implemented. It will
help to:
•identify which workers are at risk of exposure.
•determine what sources and processes are causing that risk.
•identify if and what kind of control measures should be implemented.
•check the effectiveness of existing control measures.
The following questions may help to assess the risk:
•What conditions will the operator be exposed to?
•What are the properties of the blasting medium being used?
•What is the substrate being blasted?
•What are the surface coatings of the items being blasted? E.g., do they contain toxic
metals?
•What are the conditions under which abrasive blasting is carried out (E.g., confined
spaces)?
•What are the skills, competence, and experience of the operator?

3.0: Hazards and Control Measures
3.1: Prohibited and Restricted Chemicals
The WHS Regulations prohibit and restrict the use of some hazardous chemicals as abrasive
material in an abrasive blasting process. According to WHS Regulation 381: A person
conducting a business or undertaking must not use, handle, or store, or direct a worker to
use, handle or store the hazardous chemicals (listed below) for abrasive blasting.
(Reference: Work Healthy and Safety (Abrasive Blasting) Code of Practice 2015, p.35)
3.2: Asbestos
A person conducting a business or undertaking must not use, direct or allow a worker to use
high pressure water spray or compressed air on asbestos or asbestos containing materials.

3.3: Lead
Lead may be present in surface coatings or the object being blasted. The WHS Regulations
contain specific requirements for working with lead in addition to the hazardous chemical’s
requirements. These include the identification of lead risk work and removing a worker from
lead risk work in certain circumstances.
3.4: Naturally Occurring Radioactive Material
The use of abrasives containing any radioactive substance where the level of radiation
exceeds 1 becquerels per gram (Bq/g) is prohibited, so far as reasonably practicable. You
should actively source material with lower radioactive content levels to minimise the risks
from radiation.
4.0: Identifying Dust Hazards
Abrasive blasting can generate large quantities of respirable and inhalable dust from the
abrasive blasting medium and the surface of the object being blasted. ‘Inhalable’ dust
means the dust present in the air which a worker can inhale through the nose or mouth
during breathing. ‘Respirable’ dust is that portion of inhalable dust that is small enough to
enter the lungs down to the lower bronchioles and alveolar regions. Respirable dusts may
be more hazardous than inhalable dusts for some materials, such as crystalline silica which
can result in permanent scarring of the lung tissue.
Dust hazards presented by the surface being blasted should also be considered, which could
discharge particles of hazardous chemicals. Hazards include any paint or coating on the
surface (which, for example, could contain lead) and the composition of the object or
structure being blasted (which could contain asbestos or other hazardous chemicals).
5.0: Risk and Control Measures
A combination of control measures may be required to adequately manage hazards and
associated risk with abrasive blasting. This can be achieved for example through
substitution, isolation or implementing different engineering controls. The control measures
put into place to protect health and safety should be regularly reviewed to make sure they
are effective and relevant. If not, it must be revised to ensure it is effective in controlling
risk. Please additional information please refer to the Abrasive Blasting Code of Practice
(2015).

5.1: Administrative Controls - Exclusion Zones
Although open air blasting activities are not recommended, there may be occasions where
there is no alternative. In these circumstances, exclusion zones (also known as buffer zones)
should be used to protect workers and other persons in the vicinity from exposure to
hazardous dust.
The size of the exclusion zone should be determined after assessing the risk to all
unprotected people. The prevailing conditions at the time of blasting should be considered,
for example, the exclusion zone may need to be extended down-wind. An exclusion zone
should be established and maintained to exclude workers and other persons who are not
wearing Respiratory Protective Equipment (RPE). Warning signs should be located so that
they are clearly visible before entering the area. Where an exclusion zone interferes with
other activities at a workplace, other workers should only work within the exclusion zone
after being provided with RPE.
6.0: PERSONAL PROTECTIVE EQUIPMENT (PPE)
Abrasive blasting operators must use suitable protective equipment to protect themselves
against high velocity abrasive particles. Equipment is selected to minimise risk to health and
safety by ensuring that the equipment is:
•Suitable for the nature of the work and any hazard associated with the work.
•A suitable size and fit and reasonably comfortable for the person wearing it.
•Maintained, repaired or replaced so it continues to minimise the risk.
It is important to provide the worker with information, training and instruction in the proper
use and wearing of personal protective equipment, as well as the storage and maintenance
of personal protective equipment.
➢ALWAYS ensure appropriate Personal Protective Equipment (PPE) is worn when
blasting.
PPE should include:
•CE-approved air-fed helmet
- Air for helmet must be supplied by a breathing air compressor or through a helmet
air filter
•Abrasive-resistant clothing
•Protective gloves
•Protective footwear
•Hearing protection

6.1: Respiratory protection
Workers engaged in abrasive blasting should be supplied with and wear an airline positive
pressure hood or helmet fitted with an inner bib and a high visibility shoulder cape, jacket or
protective suit. Respirator helmets must be supplied with breathing air of an adequate
quality. An air purifying respirator should also be worn by the pot attendant and any other
person within the work area while abrasive blasting is in progress, during maintenance or
repair work or during the clean-up of dust.
6.2: Helmets and eye protection
Helmets will provide protection from flying fragments to the eyes, head, and neck. Helmets
should not be held or hung up by the air feed hose, dropped or left in areas where they
might be exposed to dust and dirt or be subject to distortion. The helmet cape should be
frequently inspected, periodic cleaning and immediate replacement if damaged. Protective
eye equipment includes safety glasses, goggles, face shields, hoods or helmets with lenses
designed to withstand medium to high velocity impact by flying objects.
6.3: Protective clothing
To keep out dust and abrasive grit, protective suits or clothing should be worn and should
have leather or elastic straps at the wrist and ankles and overlapping flaps at all suit
closures. Protective gloves should be industrial safety gloves or mittens of an appropriate
material to reduce penetration of particulate matter. Protective footwear should be made
of material which reduces penetration from particulate matter, and where appropriate,
should be waterproof.
6.4: Maintenance of PPE
PPE must be maintained, repaired, or replaced to ensure that it continues to be effective.
Maintenance of PPE includes:
•Daily cleaning and inspection of PPE by the worker for wear and damage
•Identification and repair or replacement of any worn or defective components of
equipment
•Regular periodic inspection, maintenance, and testing of respiratory protective
equipment in accordance with the manufacturer’s instructions

7.0: METHOD OF OPERATION
The Burwell Abrasive Blast Machine is built in cylindrical form with the abrasive feed point,
known as the Abrasive Control Valve, located at the base of the Blast Machine Vessel. This
device is designed and engineered for the exact metering of abrasive.
At the top of the machine is the filler (pop-up) Valve (3), which floats on a guide (5). The
Valve, when closed, seats on a rubber ring (4) to ensure a leak proof condition. It will be seen
that the body of the machine is made of rolled steel with a dished end at the top and a coned
end at the base. The compressed air is fed to the machine via the Inlet Valve (1), after which
the pipe is branched, one pipe leading to the pop-up valve guide (5) to pressurise the vessel
and the other to the main airline leading to the abrasive control valve. The then pressurised
machine feeds abrasive through the base of the vessel to the abrasive control valve (2). From
there the abrasive is forced out of the "Y" piece and pot coupling (item 28) by means of the
main airline previously mentioned, into the attached blast hose and the particles normally
exit from the nozzle at approximately 650 Km/Hr.
Burwell Blast Machines are fitted with an inspection hole (6-7) for ease of maintenance. They
also have the capabilities of full adjustment of the abrasive flow.
These machines are fitted with immediate shut down "Feathertouch" Dump Valves, which,
when the trigger is released, instantaneous depressurisation occurs.
7.1: OPERATING INSTRUCTIONS
1. Connect Air Supply Hose from Compressor to inlet of Blast Machine and ensure all
safety pins and whip checks are installed.
2. Ensure Choke Valve is Open (9).
3. Ensure Pneumatic Deadman (standard) is connected.
4. Ensure Electric Deadman (if fitted) trigger cable is plugged into ECK.
5. Check condition of Nozzle and Coupling Rubbers.
5. Connect Blast Hose to Blast Machine Pot Coupling (2), ensuring all safety pins and whip
checks are installed.
7. Screw Nozzle into Nozzle Holder.
8. Ensure Moisture Trap (if fitted) is free of condensates.
9. Start Compressor.
10. Ensure Operator is wearing correct PPE.
11. Check Blast Helmet (visors, cape, air supply).
12. Depress and release trigger whilst pointing nozzle at object to be blasted to check
operation of machine.
IMPORTANT NOTES
1. Do not DROP or DRAG Deadman Switch.
2. Do not TAPE or WIRE UP Deadman Trigger.
3. Check Deadman Trigger control lines/cable for Wear or Damage daily.

TO ADJUST ABRASIVE FLOW
1. More Abrasive - Turn knob on abrasive valve anti-clockwise until you achieve
correct amount of grit
2. Less Abrasive - Turn knob abrasive valve clockwise until you achieve correct
amount of grit

8.0: TROUBLESHOOTING
PROBLEM
REMEDY
1. Abrasive will not flow from nozzle
a. Unscrew nozzle, check for blockage.
b. Dismantle hand hole cover from blast machine, check
for large foreign objects blocking outlet hole.
c. Ensure abrasive is completely dry.
d. Check Abrasive valve for blockages.
e. Use Choke valve to choke hose and clear blockage.
f. Dismantle abrasive control valve, clean, and
reassemble as per drawing attached.
2. Abrasive flowing intermittently.
a. Turn choke valve on and off in fast succession
ensuring it is in the on position when you stop.
b. Adjust abrasive control valve to desired setting.
3. Blast Machine leaks through top dish.
a. Visually check for wear on pop up valve and pop-up
valve seating rubber. If they are worn, replace them
through the hand hole.
b. Check to ensure that the pop-up valve is central to
the top hole. If not, remove hand hole and centre
the pop-up valve with a lever.
4.Dump Valve leaking during operation
a. Dismantle and check for wear. If worn, replace parts
as necessary and reassemble as per attached
drawing.
5. Machine seems to be blasting slowly and
all of the above have been checked.
a. Dismantle moisture trap (if fitted). Replace filter
element if clogged and reassemble.
b. Check compressor for output pressure.
Auto Inlet Valve may need dismantling,
cleaning, lubricating, or servicing.
6. Machine will not operate.
a. Check air supply to the machine.
b. Check for leaks in twin line.
c. Check dead man control and rubber button bumper
for seal.
7. Machine will not stop
a. Check electric cable for continual supply.
Power, use ohms meter (electric Deadman).
b. Check Manual Override Button on Solenoid (electric).
c. Check Exhaust Filter is clean.
d. Check Inlet Valve (AAV valve).

9.0:
1230 & 1532 Blast Machine Schematic
No:
PART No:
DESCRIPTION
QTY
0302-2007
Thompson II Abrasive Valve –1-1/4” (fitted to constant pressure
pots only)
1
0304-3852
Pop Up Valve
1
0404-02325
Pop Up Valve Seating Rubber
1
B48F-15
Pop Up Valve Guide (1642)
1
0304-5215
Pop Up Valve Guide (2449)
1
0304-4836
Hand Hold Cover Only
1
0304-4839
Hand Hold Cover Gasket
1
0302-6821
Micromiser Abrasive Valve 1-1/4”
1
0304-1476
Pressure Gauge, ¼” Rear Entry
1
0304-8635
Valve, Ball, 1¼" BSP, F and F
1
0601-0075
Choke Valve Hose 1-1/4"
1
0601-2146
Hose Tail, 1¼" BSP x 1" (P3)
2
0304-4810
Wheel 2801 Dia Rubber (1642 Only)
2
0304-0164
Lid for 1642 Blast Machine
1
0304-0166
Screen for 1642 Blast Machine
1
0304-2244
Lid for 2449 Blast Machine (V2.0)
1
0304-2246
Screen for 2449 Blast Machine (V2.0)
1

1230 PARTS BREAKDOWN

1230 PARTS BREAKDOWN

1532 PARTS BREAKDOWN

1532 PARTS BREAKDOWN

9.1: Valve Diagrams and Spares Listing
Air Inlet Valves –AAV 1”
NO.
OLD PART #
NEW PART #
DESCRIPTION
QTY
Assy
2123-006-99
0302-2280
Auto Air Valve 1"
Ea
2
AAV-2
0305-2802
Diaphragm
Ea
4
AAV-4
0305-2804
Retainer Bushing
Ea
5
AAV-5
0305-2805
O Ring
Ea
0305-3699
Repair Kit for 1" AAV (Consists
items 1,2,3,5,7,11,13,20,21&22)
Ea

1/2” Diaphragm Outlet/Dump Valve
NO.
OLD PART #
NEW PART #
DESCRIPTION
-
2512
0403-02512
1/2" Diaphragm Outlet Valve, complete
1
1733
0405-01733
1/2" x standard close pipe nipple
2
2511
0405-02511
1/2" Outlet valve diaphragm
3
3117
1/4" lock washer (4 required) NS
4
2513
0405-02513
1/4" x 1/4" elbow adapter
5
2299
0405-02299
1/2" Diaphragm valve cap
6
2298
0405-02298
1/2" Diaphragm valve body
7
1841
0405-01841
1" NPT x 3" T.O.E. nipple
8
3053
1/4-20 x 1" hex head cap screw NS

Micromiser Abrasive Valve (MPV 210)
No:
Part No:
Description
QTY
Assy
0302-6821
Micromiser Abrasive Valve 1-1/4” x 1-1/4”
1
1
0305-6801
Knob
1
2
0305-6802
Roll Pin
1
3
0305-6803
Bolt and Washer
1
4
0305-6804
Cap
1
5
0305-6805
Plunger*
1
6
0305-6806
Body
1
7
0305-6807
Plunger Seal*
1
8
0305-6808
Urethane Sleeve*
1
9
0305-6809
Gasket*
1
10
0305-6821
Pipe Nipple 1-1/4” x 1-1/4”
1
10
0305-0217
Pipe Nipple 1-1/4” x 1-1/2”
1
*
0305-6899
Repair Kit
1

THOMPSON II VALVE (if fitted)
NO
OLD PART NO
NEW PART NO
DESCRIPTION
QTY
2152-007
0302-2007
Thompson Valve II 1-1/4” c/w Tungsten
Carbide Sleeve
1
2152-000-01
Knob NS
1
2
2152-000-17
Breather Vent NS
1
3
2152-000-12
0305-5212
Spring Retainer
1
4
2152-000-18
0305-5218
O-Ring
1
5
7027-503-02
0302-0302
Washer
1
6
7010-507-07
Hex Bolt, 3/8” UNC 1-1/4” NS
4
7
2152-000-02
215200002
Cap Plate
1
8
2152-000-16
0305-5216
Cap Gasket
1
9
2149-000-19
2149-000-19
Bump Ring
1
10
2152-000-25
0305-5225
Vibration Disc
1
11
2152-000-03
0305-5213
Spring
1
12
2149-000-08
Nut NS
1
13
2149-000-04
0305-4904
Piston Seal
1
14
2152-000-05
0305-5205
Piston
1
15
2152-000-07
0305-5207
Tungsten Carbide Plunger
1
16
2152-000-09
0305-5209
Cylinder
1
17
2149-500-06
0305-4956
Plunger Seal (Molythene)
1
18
2152-000-06
0305-5206
Plunger Seal (Urethane)
1
19
2152-000-14
0305-5214
Body
1
20
2152-100-13
0305-52113
Urethane Sleeve
1
21a
2152-000-15
0305-5215
Base 1-1/4”, machined BSP
1
22
7010-507-95
0302-0795
Hex Bolt 3/8 x 4-3/8”
1
23
3014-505
Plug NS
1
24
2152-000-21
0305-5221
O-Ring
1
25
2152-000-13
0305-5213
Tungsten Sleeve
1
26
2152-000-10
0305-5210
Seat
1
27a
2152-000-99
0305-0099
Repair Kit, Tungsten includes Tungsten
Carbide Sleeve, O-Rings, Piston Seal,
Tungsten Carbide Plunger, Plunger Seals,
Seat, Cap Gasket
1
28a
2152-000-98
0305-5298
Seals Kit, Tungsten includes O-Rings, Piston
Seal, Plunger Seals, Seat and Cap Gasket
1