Marco BLASTMASTER SMART BOX User manual

Before using this equipment, read, understand and follow all instructions
in the Operator’s Manuals provided with this equipment. If the user and/
or assistants cannot read or understand the warnings and instructions,
the employer of the user and/or assistants must provide adequate and necessary training to
ensure proper operation and compliance with all safety procedures pertaining to this equipment. If
Operator’s Manuals have been lost, please visit www.marco.us, or contact Marco at 563.324.2519
for replacements. Failure to comply with the above warning could result in death or serious injury.
OPERATOR’S MANUAL
BLASTMASTER®SMART BOX™

Blastmaster®Smart Box
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Company Profile
Since 1944, Marco has developed a strong tradition of providing innovative and reliable products and services to the
surface preparation and protective coatings industries. We are the world’s premier provider of Abrasives, Blasting,
Coating, Dust Collectors, Engineered Systems, Rental, Safety, Service, Repair, & Modernization, and Vacuums.
Through innovative designs and a total commitment to quality, Marco manufactures products that increase production
rates, create a safer workplace, and reduce maintenance costs. Marco’s industry experience, manufacturing
capabilities, legendary customer service, product availability, logistics services, and technology leadership is your
assurance that we deliver high quality products and services, providing the best value to you, our customer.
The Marco Difference
• Industry Experience – With Marco on your team, you have access to expertise which can only come from
decades of industry leadership. We have organized our engineering department, production specialists, customer
operations, and safety support into a “Center of Competence.” As a Marco customer, you have access to hundreds
of years of cumulative experience related to your operations.
• Manufacturing Excellence – Marco is a U.S. based, ISO 9001:2008 certified manufacturer of equipment for the
Surface Preparation and Protective Coatings industries. Marco’s engineers benchmark the industry to ensure that
we design and manufacture superior products that set the “Gold Standard” for performance, safety, and quality.
• Legendary Customer Service – Marco’s legendary customer service team is staffed by friendly, highly-trained
individuals who are focused on providing the highest level of product support, order accuracy, and customer
satisfaction.
• Product Availability – We stock over 10,000 SKU’s and have more than 45 shipping locations to serve North
American and International markets for all major brands of blasting and coating equipment. As the largest provider of
surface preparation and protective coatings equipment in the world, our inventory levels and product availability are
unmatched.
• Logistics Services – Marco’s in-house logistics team is dedicated to moving your shipment anywhere in the world.
We move more than 14,000 truckloads every year, allowing you to save on freight costs by leveraging our buying
power. Lower your process costs with a single invoice, which includes product and freight.
• Technology Leadership – Our website provides: Operator’s Manuals, Part Numbers and Schematics Guides, SDS
information, and Features & Specifications Guides, providing access to information 24/7. Our Extranet application
allows you to receive quotes and place orders online. Our Intranet maintains a complete record of your purchase
history to assist with ongoing support of your existing equipment and future purchasing decisions.
Vision Statement
Marco is the world’s premier provider of Abrasives, Blasting, Coating, Dust Collectors, Engineered Systems, Rental,
Safety, Service, Repair, & Modernization, and Vacuums.
Mission Statement
Marco provides strong leadership and innovation to the surface preparation and protective coatings industries.
We dedicate our efforts to the continuous improvement of our products, services, processes, people, and most
importantly, the quality of our customer’s experience.
Quality Statement
Marco is committed to providing superior quality in the design, manufacturing, distribution, rental, service, and repair
of our products. Our ISO 9001:2008 certification extends throughout all operations in all locations. Continuous
improvement of our processes and supply chain Integration comprise the core of our business strategy for delivering
exceptional quality and value in all Marco products and services.
Management Philosophy
We are a company dedicated to the success of every customer and associate. We discuss, debate, challenge,
measure, and test our ideas. We will be boundless and limitless in our passion to improve. Through sound
leadership and dedicated associates, we will ensure a long term, profitable future for Marco, our associates,
customers, and suppliers.

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Company Prole . . . . . . . . . . . . . . . . . . . . . . . . . 1
Denition of Terms . . . . . . . . . . . . . . . . . . . . . . 2
Hazard Identications . . . . . . . . . . . . . . . . . . . 3
Air & Abrasive Consumption Chart . . . . . . . 6
Daily Pre-Operation Checklist . . . . . . . . . . . . 8
Operating Instructions . . . . . . . . . . . . . . . . . . . 9
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operational Requirements . . . . . . . . . . . . . . . . . 9
Production Timers. . . . . . . . . . . . . . . . . . . . . . . 11
Reset Production Timers . . . . . . . . . . . . . . . . . 12
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Install Blastmaster Smart Box on Bulk
Abrasive Blasting Pot . . . . . . . . . . . . . . . . . . . . 13
Install Pressure Indicator - Bulk Abrasive
Blasting Pot . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Install Pressure Indicator - 6.5 cu. ft. and
Smaller Abrasive Blasting Pots. . . . . . . . . . . . . 15
Install Pressure Switch - Blastmaster 125E &
125P Remote Control System . . . . . . . . . . . . . 16
Install Pressure Switch - Blastmaster 123E &
123P Remote Control System . . . . . . . . . . . . . 17
TABLE OF CONTENTS
DEFINITION OF TERMS
This is an example of a warning. This indicates a
potentially hazardous situation which, if not avoided,
could result in death or serious injury.
This is an example of a notice. This indicates policy
or practice directly related to safety of personnel or
protection of property.
This is an example of danger. This indicates an
imminently hazardous situation which, if not avoided, will
result in death or serious injury.
This is an example of a caution. This indicates a
potentially hazardous situation which, if not avoided,
may result in minor or moderate injury. It can also be
used to alert against unsafe practices.
Install Pressure Switch - Blastmaster 130P
Remote Control System . . . . . . . . . . . . . . . . . . 18
Install Pressure Switch - Blastmaster 130E
Remote Control System . . . . . . . . . . . . . . . . . . 19
Install Pressure Switch - Blastmaster 120E &
120P Remote Control System . . . . . . . . . . . . . 20
Connecting Outlets . . . . . . . . . . . . . . . . . . . . . . 21
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibrate Digital Pressure Display . . . . . . . . . . 22
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 23
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . 26
Disclaimer of Warranty . . . . . . . . . . . . . . . . . . . 26
Exclusive Remedy for Warranty Claims . . . . . . 26
Limitation of Remedies . . . . . . . . . . . . . . . . . . . 26

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Failure to comply with ANY WARNING listed below could result in death or serious injury.
OSHA sets exposure limits to protect workers from exposure to respirable crystalline silica, 29 CFR 1910.1053.
Airborne dust could increase the exposure levels beyond permissible limits. Breathing dust containing silica
could cause silicosis, a fatal lung disease. Breathing dust during abrasive blasting operations, post-blast cleaning
operations, and/or servicing equipment within the abrasive blasting area may expose an individual to conditions
that could cause asbestosis, lead poisoning and/or other serious or fatal diseases. Harmful dust containing toxic
material from abrasives or surfaces being abrasive blasted can remain suspended in the air for long periods of
time after abrasive blasting has ceased. A NIOSH-approved, well-maintained, respirator designed for the specific
operation being performed must be used by anyone abrasive blasting, handling or using the abrasive, and
anyone in the area of the dust.
Contact NIOSH and OSHA offices to determine the proper respirator for your specific application. The air supplied
to the respirator must be at least Grade D quality as described in Compressed Gas Association Commodity
Specification G-7.1 and as specified by OSHA Regulation 1910.134. Ensure air filter and respirator system hoses
are not connected to non-air sources or in-plant lines that may contain nitrogen, oxygen, acetylene or other
non-breathable gases. Before removing respirator, use an air monitoring instrument to determine if the
atmosphere is safe to breathe.
You must comply with all OSHA, local, City, State, Province, Country and jurisdiction regulations, ordinances and
standards, related to your particular work area and environment. Keep unprotected individuals out of the work
area.
Abrasive blasting operators must receive thorough training on the use of abrasive resistant attire which includes:
supplied-air respirator, abrasive blasting suit, safety shoes, gloves, ear protection and eye protection. Protect the
operator and bystanders by complying with NIOSH and OSHA Safety Standards.
Inspect all equipment for wear or damage before and after each use. Failure to use Original Equipment
Manufacturer repair parts and failure to immediately replace worn or damaged components could void warranties
and cause malfunctions.
OSHA requires abrasive blasting nozzles be equipped with an operating valve, which shall be designed to be
held open only by continuous hand pressure and shall close immediately upon release of hand pressure (i.e., a
“deadman” control). The valve shall not be modified in any manner that would allow it to remain open without the
application of continuous hand pressure by the operator. Failure to comply with the above warning could result in
release of high speed abrasive and compressed air resulting in death or serious injury. OSHA 29CFR 1910.244(b)
Point the abrasive blasting nozzle only at the surface being abrasive blasted. Never point the abrasive blasting
nozzle or abrasive stream at yourself or others.
Unless otherwise specified, maximum working pressure of abrasive blasting pots and related components must
not exceed 150 psi. Exceeding maximum working pressure of 150 psi could cause the abrasive blasting pot and
components to burst. Failure to comply with the above warning could result in death or serious injury.
Never weld, grind or drill on the abrasive blasting pot (or any pressure vessel). Doing so will void ASME
certification and manufacturer’s warranty. Welding, grinding or drilling on the abrasive blasting pot (or any pressure
vessel) could weaken the vessel causing it to burst. Failure to comply with the above warning could result in death
or serious injury. (ASME Pressure Vessel Code, Section VIII, Division 1)
This equipment is not intended for use in any area that might be considered a hazardous location, as described
in the National Electric Code NFPA 70, Article 500. Use of this equipment in a hazardous location could cause an
explosion or electrocution.
Never attempt to move an abrasive blasting pot containing abrasive. Never attempt to manually move abrasive
blasting pots greater than 6.5 cubic foot capacity. Always use at least two capable people to manually move an
abrasive blasting pot on flat, smooth surfaces. A mechanical lifting device must be used if an abrasive blasting pot
is moved in any other manner.
HAZARD IDENTIFICATIONS

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HAZARD IDENTIFICATIONS
Failure to comply with ANY WARNING listed below could result in death or serious injury.
This product is not for use in wet environments. Always use a Ground Fault Interrupter Circuit (GFIC) for
all electrical power source connections. Use of this product in wet environments could create a shock or
electrocution hazard.
Frozen moisture could cause restrictions and obstructions in pneumatic control lines. Any restriction or
obstruction in the pneumatic control lines could prevent the proper activation and deactivation of the remote
control system, resulting in the release of high speed abrasive and compressed air. In conditions where moisture
may freeze in the control lines an antifreeze injection system approved for this application can be installed.
Do not cut, obstruct, restrict or pinch pneumatic control lines. Doing so could prevent the proper activation and
deactivation of the remote control system, resulting in the release of high speed abrasive and compressed air.
Use of Marco remote control switches with other manufacturer’s remote control systems could cause unintended
activation of remote control systems resulting in the release of high speed abrasive and compressed air. Only
Marco remote control switches should be used with Marco remote control systems.
Always be certain to have secure footing when abrasive blasting. There is a recoil hazard when abrasive blasting
starts that may cause user to fall and misdirect the abrasive stream at operator or bystander.
Never use an abrasive blasting pot or attachments as a climbing device. The person could slip and fall. The
abrasive blasting pot could become unstable and tip over.
For equipment manufactured by entities other than Marco, you must consult the Original Equipment Manufacturer
operator’s manuals, information, training, instructions and warnings, for the proper and intended use of all
equipment.
Flammable fumes, such as solvent and paint fumes in the work area can present an ignition or explosion hazard
if allowed to collect in adequate concentrations. To reduce conditions that could result in a fire or an explosion,
provide adequate ventilation, eliminate all ignition or spark sources, keep the work area free of debris, store
solvents and solvent contaminated rags in approved containers, follow proper grounding procedures, do not
plug/unplug power cord or turn on/off power switches when flammable fumes are present, keep a working fire
extinguisher or provide another fire suppression system in the work area. Cease all operations and correct
condition if a spark or ignition source is identified during operation.
Always depressurize the entire system, disconnect all power sources and lockout/tagout all components before
any maintenance or troubleshooting is attempted. Failure to comply with the above warning could cause electrical
shock and inadvertent activation of equipment resulting in death or serious injury.
Moving parts can present an area where crushing, pinching, entanglement or amputation may occur. Do not
place body parts or foreign objects in any area where there are moving parts.
Surfaces of heated supply tanks, drums and/or lines as well as the adjoining plumbing may become hot during
normal use. Do not touch these heated surfaces without proper protection. Deactivate and allow sufficient time for
all surfaces to cool before attempting any maintenance.
High-pressure fluid from gun, hose leaks, or ruptured components can pierce skin and can cause a serious injury
that may result in amputation. Do not point gun or spray tip at anyone or at any part of the body. Keep clear
of any leaks or ruptures. Depressurize the entire system before attempting cleaning, inspecting, or servicing
equipment.
Exposure to toxic fluids or fumes may occur during the normal operation of this system. Before attempting to
fill, use, or service this system, read SDS’s to know the specific hazards of the fluids you are using. Always use
proper Personal Protective Equipment when attempting to fill, use, or service this system.
The use of this product for any purpose other than originally intended or altered from its original design is
prohibited.
Never hang objects from the abrasive blasting pot handle. Doing so may cause the abrasive blasting pot to
become unstable and tip over.

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HAZARD IDENTIFICATIONS
Failure to comply with ANY CAUTION listed below may result in minor or moderate injury.
Static electricity can be generated by abrasive moving through the abrasive blasting hose causing a shock
hazard. Prior to use, ground the abrasive blasting pot and abrasive blasting nozzle to dissipate static electricity.
High decibel noise levels are generated during the abrasive blasting process which may cause loss of hearing.
Ensure appropriate Personal Protective Equipment and hearing protection is in use.
Failure to comply with ANY NOTICE listed below could pose a hazard to personnel or property.
See Air & Abrasive Consumption Chart for estimated abrasive consumption rates and required air flow (cubic feet
per minute). Your system must meet these minimum requirements to ensure proper function and performance.
Always use abrasive that is dry and properly screened. This will reduce the potential for obstructions to enter the
remote control system, abrasive metering valve and abrasive blasting nozzle.
Moisture build-up occurs when air is compressed. Any moisture within the abrasive blasting system will cause
abrasive to clump, clogging metering valves, hoses and nozzles. Install an appropriately sized moisture separator
at the inlet of the abrasive blasting system. Leave the moisture separator petcock slightly open to allow for
constant release of water. If insufficient volume of air exists and petcock is unable to be left open (at all times)
petcock should be opened frequently to release water.
To reduce abrasive intrusion in the air supply hose, depressurize the abrasive blasting pot before shutting off air
supply from compressor.
Inspect abrasive blasting nozzle before placing into service. Damage to abrasive blasting nozzle liner or
jacket may occur during shipping. If you receive a damaged abrasive blasting nozzle, contact your distributor
immediately for replacement. Abrasive blasting nozzles placed into service may not be returned. Abrasive blasting
nozzle liners are made of fragile materials and can be damaged by rough handling and striking against hard
surfaces. Never use a damaged abrasive blasting nozzle.
Abrasive blasting at optimal pressure for the abrasive used is critical to productivity. Example: For an abrasive
with an optimal abrasive blasting pressure of 100 psi at the abrasive blasting nozzle, one pound per square inch
of pressure loss will reduce abrasive blasting efficiency by 1.5%. A 10 psi reduction in air pressure will cause a
15% loss of efficiency. Use a Needle Pressure Gauge to identify pressure drops in your system. Consult with your
abrasive supplier for the requirements of your abrasive.
Replace abrasive blasting nozzle if liner or jacket is cracked or damaged. Replace abrasive blasting nozzle if
original orifice size has worn 1/16” or more. Determine abrasive blasting nozzle wear by inserting a drill bit 1/16”
larger than original size of abrasive blasting nozzle orifice. If the drill bit passes through abrasive blasting nozzle,
replacement is needed.

Blastmaster®Smart Box 6
Failure to comply with ANY NOTICE listed below could pose a hazard to personnel or property.
See Air & Abrasive Consumption Chart for estimated abrasive consumption rates and required air flow
(cubic feet per minute). Your system must meet these minimum requirements to ensure proper function and
performance.
When it comes to air & abrasive mixtures, more is not necessarily better. Optimum abrasive blasting efficiency
takes place when a lean air & abrasive mixture is used. To correctly set the abrasive metering valve, begin
with the valve fully closed and slowly increase the amount of abrasive entering the airstream. As you increase
the abrasive flow, watch for a “blue flame” at the exit of the abrasive blasting nozzle. Faster cutting, reduced
abrasive consumption and lower clean up costs, are benefits of the “blue flame”.
Abrasive blasting at optimal pressure for the abrasive used is critical to productivity. Example: For an abrasive
with an optimal abrasive blasting pressure of 100 psi at the abrasive blasting nozzle, one pound per square inch
of pressure loss will reduce abrasive blasting efficiency by 1.5%. A 10 psi reduction in air pressure will cause a
15% loss of efficiency. Use a Needle Pressure Gauge to identify pressure drops in your system. Consult with
your abrasive supplier for the requirements of your abrasive.
*Abrasive consumption is based on abrasive with a bulk density of 100 lbs per Cubic Foot
Air & Abrasive Consumption Chart*
Nozzle
Orifice
Pressure at the Nozzle (PSI) Air (in cfm), Abrasive
& Compressor
Requirements
50 60 70 80 90 100 125 140
No. 2
(1/8ˮ)
11
67
2.5
13
77
3
15
88
3.5
17
101
4
18
112
4.5
20
123
5
25
152
5.5
28
170
6.2
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 3
(3/16ˮ)
26
150
6
30
171
7
33
196
8
38
216
9
41
238
10
45
264
10
55
319
12
62
357
13
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 4
(1/4ˮ)
47
268
11
54
312
12
61
354
14
68
408
16
74
448
17
81
494
18
98
608
22
110
681
25
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 5
(5/16ˮ)
77
468
18
89
534
20
101
604
23
113
672
26
126
740
28
137
812
31
168
982
37
188
1100
41
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 6
(3/8ˮ)
108
668
24
126
764
28
143
864
32
161
960
36
173
1052
39
196
1152
44
237
1393
52
265
1560
58
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 7
(7/16ˮ)
147
896
33
170
1032
38
194
1176
44
217
1312
49
240
1448
54
254
1584
57
314
1931
69
352
2163
77
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 8
(1/2ˮ)
195
1160
44
224
1336
50
252
1512
56
280
1680
63
309
1856
69
338
2024
75
409
2459
90
458
2754
101
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 10
(5/8ˮ)
308
1875
68.5
356
2140
79.5
404
2422
90
452
2690
100.5
504
2973
112
548
3250
122
663
3932
146
742
4405
165
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
No. 12
(3/4ˮ)
432
2672
96
504
3056
112
572
3456
127
644
3840
143
692
4208
154
784
4608
174.5
948
5570
209
1062
6238
236
Air (cfm)
Abrasive (lbs/hr)
Compressor Horsepower
Inspect abrasive
blasting nozzle before
placing into service.
Damage to abrasive
blasting nozzle liner
or jacket may occur
during shipping. If you
receive a damaged
abrasive blasting nozzle,
contact your distributor
immediately for
replacement. Abrasive
blasting nozzles placed
into service may not
be returned. Abrasive
blasting nozzle liners
are made of fragile
materials and can be
damaged by rough
handling and striking
against hard surfaces.
Never use a damaged
abrasive blasting nozzle.
Replace abrasive
blasting nozzle if liner
or jacket is cracked
or damaged. Replace
abrasive blasting nozzle
if original orifice size
has worn 1/16” or more.
Determine abrasive
blasting nozzle wear by
inserting a drill bit 1/16”
larger than original size
of abrasive blasting
nozzle orifice. If the
drill bit passes through
abrasive blasting nozzle,
replacement is needed.
“Blue Flame”
AIR & ABRASIVE CONSUMPTION CHART

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“THE BIG PICTURE”
3
5
7
4
4
3
21
8
9
17
14
1615
13
19
18
10
20
23
21
424
27
26
25
22
28
5
3
6
11
12

Blastmaster®Smart Box 8
Daily Pre-operation Checklist
1. Abrasive
2. Air Compressor
3. Air Hose Couplings & Gaskets
4. Air Hose
5. Safety Cable
6. Ambient Air Pump*
7. Breathing Air Filter
8. CO Monitor
9. Breathing Line
10. Climate Control Device
11. Abrasive Blasting Suit
12. Gloves
13. Abrasive Blasting Nozzle
14. Lighting System*
15. Abrasive Blasting Nozzle Holder
16. Remote Control Switch
17. Supplied-Air Respirator
18. Control Line
19. Abrasive Blasting Hose
20. Abrasive Blasting Hose
Couplings & Gaskets
21. Abrasive Metering Valve
22. Remote Control System
23. Moisture Separator
24. Abrasive Blasting Pot Exhaust
Muffler
25. Abrasive Blasting Pot
26. Abrasive Blasting Pot Screen
27. Abrasive Blasting Pot Lid
28. Aftercooler*
* Optional or alternative device.
Ask your Marco Representative
for more details.
Abrasive – Select the correct Abrasive (1) for the application. Review the SDS
(Safety Data Sheet) to ensure the correct PPE (Personal Protective Equipment)
and Environmental Controls have been selected and are in place.
Air Compressor – Select an Air Compressor (2) of adequate size to support all
equipment requirements. Refer to “Air & Abrasive Consumption Chart” for
Abrasive Blasting Nozzle (13) air consumption requirements. Before connecting
Air Hose (4), sample the air being produced by the air compressor (2) to ensure
it is free of petroleum contaminants.
Air Hose, and Air Hose Couplings & Gaskets – Select Air Hoses (4) of
sufficient size to support all subsequent volumetric requirements and with a
sufficient PSI (pound per square inch) rating. Inspect all Air Hoses (4), and Air
Hose Couplings & Gaskets (3) for damage or wear. Repair or replace damaged
or worn components.
Abrasive Blasting Hose, Abrasive Blasting Hose Couplings & Gaskets, and
Abrasive Blasting Nozzle Holder – Select an Abrasive Blasting Hose (19) that
has an inner diameter 3 to 4 times larger than your Abrasive Blasting Nozzle
(13). Inspect Abrasive Blasting Hose (19), Abrasive Blasting Hose Couplings
& Gaskets (20), and Abrasive Blasting Nozzle Holder (15) for damage or wear.
Repair or replace damaged or worn components.
Safety Cables – Install a Safety Cable (5) at each Abrasive Blasting Hose (19),
and Air Hose (4) connection points.
Aftercooler and Moisture Separator – Ensure Aftercooler (28) is positioned
on stable ground. Keep petcock drain of Moisture Separator (23) slightly open
during use. Drain both devices after each use.
Supplied-Air Respirator, Breathing Line, Breathing Air Filter, Climate
Control Device, CO Monitor, Ambient Air Pump – You MUST consult the
Operator’s Manual supplied with your Respiratory Equipment (6, 7, 8, 9,
10, 17) for ALL applicable instructions and warnings. Inspect all Respiratory
Equipment components for damage or wear. Repair or replace damaged or worn
components.
Abrasive Blasting Suit and Gloves – Select an abrasive-resistant Abrasive
Blasting Suit (11) that is slightly oversized to allow ease of movement and allows
air to flow around your body. Select abrasive-resistant Gloves (12) with a tight fit
and a long cuff that overlaps the sleeve of the Abrasive Blasting Suit (11).
Abrasive Metering Valve and Abrasive Blasting Pot – Confirm Abrasive
Blasting Pot (25) is positioned on stable ground. Inspect Abrasive Blasting Pot
(25) and Abrasive Metering Valve (21) for damage or wear. Repair or replace
damaged or worn components.
Abrasive Blasting Pot Screen and Abrasive Blasting Pot Lid – Always use
an Abrasive Blasting Pot Screen (26) when filling Abrasive Blasting Pot (25)
with Abrasive (1) to prevent debris from entering the Abrasive Blasting Pot (25).
Remove Abrasive Blasting Pot Lid (27) before operating the Abrasive Blasting
Pot (25). Install Abrasive Blasting Pot Lid (27) after use to protect the Abrasive
Blasting Pot’s (25) interior.
Remote Control System, Remote Control Switch, Control Line, – Inspect
Remote Control System (22) and Control Line (18) for damage or wear. Repair
or replace damaged or worn components. Ensure Control Line (18) fittings
connected to the Remote Control System (22) are tight and free of leaks. Ensure
Remote Control Switch (16) is functioning properly. Consult Remote Control
Switch Operator's Manual for applicable instructions.
Abrasive Blasting Pot Exhaust Muffler – Inspect Abrasive Blasting Pot
Exhaust Muffler (24) at start and end of daily use. Replace element of Abrasive
Blasting Pot Exhaust Muffler (24) per Operator's Manual instructions.
Lighting System – Ensure the Lighting System (14) is connected to a proper
power supply before use.
DAILY PRE-OPERATION CHECKLIST

Blastmaster®Smart Box
9
OPERATING INSTRUCTIONS
Description
The Blastmaster®Smart Box™ Production Management System records overall vessel
pressurization time and the duration of activation on up to four individual remote control
systems to monitor individual operator efficiency. A Marco®exclusive, patented device,
the Blastmaster Smart Box Production Management System records each time a blast
pot is pressurized and when an operator activates a remote control switch. This collected
data can be used to calculate operational efficiency of abrasives and operators, create a
proactive maintenance program, and helps improve accuracy of job-costing and estimations
for future projects. Typical applications include blast rooms, blast yards, bridges, offshore
platforms, oil refineries, pipelines, and storage tanks.
Operational Requirements
The following may cause safety hazards or reduced performance:
• Incorrect power source.
• Improper installation.
• Damaged components.
Before use:
• Install Blastmaster Smart Box to suitable protected location.
• Connect pressure switch to each outlet on the abrasive blasting pot moisture separator.
See Maintenance section.
• Connect pressure switch to pressure indicator outlet of abrasive blasting pot. See
Maintenance section.
• Connect Pressure Transducer (3) to appropriate fitting. See Installation Instructions.
• Connect Outlet (4) to 12-Volt DC power source.
• Verify following items are now illuminated:
• “DEPRESSURIZED” Indicator Light (7).
• “TANK PRESSURE” Display (1).
• “DAILY PRODUCTION” Timers (2).
• “TOTAL TIME PRESSURIZED” Timers (5).
• Pressurize abrasive blasting pot. See abrasive blasting pot Operator’s Manual.
During use:
• When abrasive blasting pot is pressurized greater than 3 PSI, Red indicator light (8) will
activate, alerting operator that the abrasive blasting pot is under pressure.
• Blue Indicator Light (6) for each connected operator will turn on when remote control
switch is activated. Blue Indicator Light will turn off when remote control switch is
deactivated.
After use:
• Depressurize abrasive blasting pot. See abrasive blasting pot Operator’s Manual.
• When the Pot Pressure indicator light changes from red to green, the abrasive blasting
pot is depressurized.
The use of this product
for any purpose other
than originally intended
or altered from its
original design is
prohibited. Failure to
comply with the above
warning could result in
death or serious injury.
W-520
You must comply
with all OSHA, local,
City, State, Province,
Country and jurisdiction
regulations, ordinances
and standards, related
to your particular work
area and environment.
Keep unprotected
individuals out of the
work area. Failure to
comply with the above
warning could result in
death or serious injury.
W-503
Read, understand, and
follow the Original
Equipment Manufacturer
operator’s manuals,
information, training,
instructions, and
warnings, for the proper
and intended use of all
equipment. Failure to
comply with the above
warning could result in
death or serious injury.
W-594
Blastmaster®Smart
Box™Pressure Indicator
light does not portray
operating state of the
abrasive blasting pot.
Always depressurize
abrasive blasting pot per
instructions in abrasive
blast pot operators
manual. Failure to
comply with the above
warning could result in
death or serious injury.
W-593

Blastmaster®Smart Box 10
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
OPERATING INSTRUCTIONS
8
1
2
3
4
5
6
7

Blastmaster®Smart Box
11
Total Production Timer:
1) When Abrasive Blasting Pot is pressurized the red “PRESSURIZED” LED (4) is lit.
2) While Abrasive Blasting Pot is pressurized “TOTAL TIME PRESSURIZED” Timer (2) will
activate and the red “PRESSURIZED” LED (4) will remain lit.
3) Verify timers are active. An hour glass is displayed in the top left corner to indicate they
are counting.
Daily Production Timers:
1) When Abrasive Blasting Pot is pressurized the red “PRESSURIZED” LED (4) will be lit.
2) Once an outlet has been activated by an operator the correlating “DAILY
PRODUCTION” Timer (1) will activate and the blue “ACTIVE” LED (3) will be lit.
3) Verify timers are active. An hour glass is displayed in the top left corner to indicate they
are counting.
Note: The timers count in increments of 6 minutes:
0.1 = 6 minutes
0.5 = 30 minutes
1.0 = 1 hour
OPERATING INSTRUCTIONS
Blastmaster®Smart
Box™Pressure Indicator
light does not portray
operating state of the
abrasive blasting pot.
Always depressurize
abrasive blasting pot per
instructions in abrasive
blast pot operators
manual. Failure to
comply with the above
warning could result in
death or serious injury.
W-593
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
3
2
4
Production Timers
1

Blastmaster®Smart Box 12
OPERATING INSTRUCTIONS
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Reset Production Timers
Daily Production Timers:
1) Open Cover (1).
2) Select display to reset. Push and hold correlating Reset Button (2) wait three seconds
then release. This will reset Daily Production Timer (3) for one operator. Repeat
procedure for other operators.
1
5
4
2
3
Total Production Timer:
1) Open Cover (1).
2) Insert key into Key Switch (5).
3) Turn key clockwise and hold for 3 seconds.
4) Turn key back to vertical position and remove from Key Switch (5). This will reset Total
Production Timer (4).

Blastmaster®Smart Box
13
INSTALLATION
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Blastmaster Smart Box on Bulk Abrasive Blasting Pot
Note: Additional components may be required to install Blastmaster Smart Box.
1) Install Enclosure (10) to Upper Bracket (4) using Bolts, Washers, and Lock Nut (1, 2, 3).
Repeat for Lower Bracket (9).
2) With Enclosure (10) attached, mark Hole Locations (A) on Abrasive Blasting Pot Leg
(8).
3) Drill holes previously marked.
4) Install assembly using Bolts, Washers, and Lock Nuts (5, 6, 7).
1,2,3
5,6,7
4
5,6,7
7
3
1
2
5,6,7
6
6
5
2
9
10
8
A

Blastmaster®Smart Box 14
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Indicator - Bulk Abrasive Blasting Pot
Note: Additional components may be required to install Pressure Switch.
1) Disconnect Blastmaster 190 Assembly (1) from Watts Strainer (6).
2) Install Pipe tee (2) on Blastmaster 190 Assembly (1).
3) Install Pressure Sensor (8) on Pipe Tee (2).
4) Install Hex Nipple (3) on Pipe Tee (2).
5) Install Pipe Tee (4) on Hex Nipple (3).
6) Install Pressure Transducer (7) on Pipe Tee (4).
7) Install Hex Nipple (5) on Pipe Tee (4)
8) Install Watts Strainer (6) on Hex Nipple (5).
123
6
45
7
8

Blastmaster®Smart Box
15
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Indicator - 6.5 cu. ft. and Smaller Abrasive Blasting Pots
Note: Additional components may be required to install Pressure Switch.
1) Remove and retain Ball Valve (3) from Moisture Separator (9).
2) Install Pipe Tee (1) on Moisture Separator (9).
3) Install Pipe Nipple (2) and Bushing (4) on Pipe Tee (1).
4) Install Hex Nipple (5) on Bushing (4).
5) Install Pipe Tee (7) on pipe nipple (5).
6) Install Pressure Transducer (6) on Pipe Tee (7).
7) Install Pressure Sensor (8) on Pipe Tee (7).
8) Install Ball Valve (3) on Pipe Nipple (2)
123
4
5
6
7
8
9

Blastmaster®Smart Box 16
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Switch - Blastmaster 125E & 125P Remote Control
System
Note: Additional components may be required to install Pressure Switch.
1) Remove and retain 90º Pipe Elbow (5) from Inlet Valve (1).
2) Install Hex Nipple (2) on Inlet Valve (1).
3) Install Pipe Tee (4) on Hex Nipple (2).
4) Install Pressure Switch (3) on Pipe Tee (4).
5) Install 90º Pipe Elbow (5) on Pipe Tee (4).
1
2
3
4
5

Blastmaster®Smart Box
17
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Switch - Blastmaster 123E & 123P Remote Control
System
Note: Additional components may be required to install Pressure Switch.
1) Remove and retain 90º Pipe Elbow (1) from Tandem Remote Control Valve (5).
2) Install Hex Nipple (4) on Tandem Remote Control Valve (5).
3) Install Pipe Tee (6) on Hex Nipple (4).
4) Install Pressure Switch (3) on Pipe Tee (4).
5) Install Hex Nipple (2) on Pipe Tee (6).
6) Install 90º Pipe Elbow (1) on Hex Nipple (2).
2
3
4
5
6
1

Blastmaster®Smart Box 18
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Switch - Blastmaster 130P Remote Control System
Note: Additional components may be required to install Pressure Switch.
1) Remove and retain Hose Fitting (5) from Swivel Fitting (1).
2) Install Hex Nipple (2) on Swivel Fitting (1).
3) Install Pipe Tee (4) on Hex Nipple (2).
4) Install Pressure Switch (3) on Pipe Tee (4).
5) Install 90º Pipe Elbow (6) on Pipe Tee (4).
6) Reinstall the hose fitting (5) to the 90º pipe elbow (6).
1
3
4
6
5
2

Blastmaster®Smart Box
19
INSTALLATION
Apply pipe thread
sealant to all pipe
threads to ensure an
airtight seal.
N-519
Always depressurize
the entire system,
disconnect all power
sources and lockout/
tagout all components
before any maintenance
or troubleshooting is
attempted. Failure to
comply with the above
warning could cause
electrical shock and
inadvertent activation of
equipment resulting in
death or serious injury.
W-562
Install Pressure Switch - Blastmaster 130E Remote Control System
Note: Additional components may be required to install Pressure Switch.
1) Remove and retain Hose Fitting (5) from Swivel Fitting (1).
2) Install Hex Nipple (2) on Swivel Fitting (1).
3) Install Pipe Tee (4) on Hex Nipple (2).
4) Install Pressure Switch (3) on Pipe Tee (4).
5) Install 90º Pipe Elbow (6) on Pipe Tee (4).
6) Install Hose Fitting (5) on 90º Pipe Elbow (6).
1
3
4
6
5
2