Panblast BP600-3 User manual

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PRODUCTOPERATINGMANUAL
PANBLASTTM
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BP600‐3BLASTPOT
ManualNumber:ZVP‐PC‐0154‐00
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SECTION
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1. GENERAL INFORMATION
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2. INITIAL SETUP INSTRUCTIONS
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3. OPERATING INSTRUCTIONS
4. MAINTENANCE
5. TROUBLE SHOOTING GUIDE
6. ASSEMBLIES, PARTS LISTING & EXPLODED VIEW
7. COPY OF BLAST POT SHELL CERTIFICATE (IF APPLICABLE)
BLAST POT SERIAL NUMBER:
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ZVP-PC-0154-00-R1
1.0 GENERAL INFORMATION
1.1 Panblast notice to purchasers and users
1.1.1 All products and equipment designed and
manufactured by Panblast are intended for use
by experienced users of abrasive blasting
equipment and its associated operations and
abrasive blasting media.
1.1.2 It is the responsibility of the user to:
- Determine if the equipment and abrasive
media is suitable for the users' intended
use and application.
- Familiarize themselves with any appropriate
laws, regulations and safe work practices,
which may apply within the users working
environment.
- Provide appropriate operator training and a
safe working environment including
operator protective equipment (PPE) such as,
but not limited to, safety footwear,
protective eyewear and hearing protection.
1.1.3 Panblast Standard Terms and Conditions of Sale
apply. Contact your local Panblast office should
you require any further information or
assistance.
1.2 ! WARNING! – READ THIS SECTION
CAREFULLY BEFORE USING THIS
EQUIPMENT/APPARATUS.
1.2.1 Heavy metal paint, asbestos and other toxic
material dusts will cause serious lung disease or
death without the use of properly designed and
approved supplied air respiratory equipment
(SAR) by blast operators and all personnel within
the work site area.
1.2.2 The compressor must have adequate output and
the plumbing between the compressor and the
point of attaching the air supply hose must have
sufficient capacity to supply the volume of air at
the pressure required.
1.3 Standard safety precautions
1.3.1 Approved safety eyewear, hearing and footwear
protection should be worn at all times by the
operator and all personnel in the immediate
area that may be exposed to any hazards
generated by the abrasive blasting process.
1.3.2 Suitably approved respiratory protection should
also be worn when handling abrasive media,
abrasive refuse dust and when carrying out any
service/maintenance work where any dust may
be present.
1.3.3 Any work performed on electrical wiring or
components must only be carried out by
suitably qualified and registered electrical
trade’s personnel.
1.3.4 Under no circumstances should any safety
interlocks/lockouts or features be altered or
disabled in any way.
1.3.5 All equipment must be isolated from the
compressed air supply and electrical power prior
to any service or maintenance work being
carried out.
1.3.6 All care must be taken by the operator(s) when
lifting or moving equipment or components in
order to prevent injury. Blast pots must always
be emptied of abrasive media before any
attempt is made to move them.
1.3.7 Any modification of the equipment and/or
components or use of non-genuine PanBlast™
replacement parts will void warranty.
1.3.8 Always check the Material Safety Data Sheet
(MSDS) on the abrasive media being used to
ensure that it is free of harmful substances, in
particular, free silica, cyanide, arsenic or lead.
1.3.9 Test the surface to be blasted for harmful
substances, taking the appropriate measures to
ensure the safety of the operator and others
1.3.10 The operator should carry out a daily inspection
of all related components prior to startup of all
wearing and safety items to ensure they are in
correct operating order. In particular check all
hose couplings and nozzle holders, ensuring
that all hose couplings are fitted correctly and
the safety locking pins are engaged and in good
order. Always install safety whip check cables at
every hose connection. Ensure that the blast
nozzle has been securely screwed into the
nozzle holder and the nozzle holder has been
secured to the blast hose correctly and all
screws are engaged.
NOTE: UNDER OSHA 1915:34(c)(1)(iv) DEAD
MAN CONTROL. A DEADMAN CONTROL
DEVICE SHALL BE PROVIDED AT THE NOZZLE
END OF THE BLAST HOSE EITHER TO PROVIDE
DIRECT CUTOFF OR TO SIGNAL THE POT
TENDER BY MEANS OF A VISUAL AND
AUDIBLE SIGNAL TO CUT OFF THE FLOW, IN
THE EVENT THE BLASTER LOSES CONTROL OF
THE HOSE. THE POT TENDER SHALL BE
AVAILABLE AT ALL TIMES TO RESPOND
IMMEDIATELY TO THE SIGNAL.
2.0 INITIAL SET UP INSTRUCTIONS
2.1 Blast pot initial set up
2.1.1 Position the blast pot in the location where it is
to be used, preferably on a flat, level surface.
Never attempt to move the blast pot when it is
full of abrasive media.
2.1.2 Fit the blast hose coupling and nozzle holder to
the blast hose, ensuring that the ends of the
blast hose are cut square and flat. The blast
hose coupling and nozzle holder must be
pushed/twisted up onto the blast hose until the
end of the blast hose is firmly up against the
inside step located inside the blast hose
coupling and nozzle holder. Then install the
screws supplied with the blast hose coupling
and nozzle holder to ensure that they are
securely fitted to the blast hose.
! WARNING! – NEVER OPERATE/USE A BLAST
HOSE WITHOUT THE BLAST HOSE COUPLING
AND NOZZLE HOLDER FITTED IN THE
CORRECT MANNER.
2.1.3 Once fitment of the blast hose fittings is
completed, connect the blast hose coupling to
the abrasive metering valve coupling located at
the bottom of the blast pot, making sure that
the coupling safety locking pins are correctly
fitted and form an airtight sealbetween the two
couplings. Then lay the blast hose out flat for its
full length.

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ZVP-PC-0154-00-R1
2.1.4 Securely attach a suitably sized compressed air
line to the blast pot main air supply ball valve,
ensuring that the main air supply ball valve is in
the closed position. It is preferable for the
compressed air line to be at least one size larger
than the piping size on the blast pot. Ensure
that all coupling safety locking pins and/or
locks are correctly fitted to the compressed air
connection. Panblast recommends the use of
correctly sized safety whip check cables at all
compressed air line and blast hose connections.
2.1.5 Check that the nozzle holder rubber washer is
correctly installed then screw the blast nozzle
fully into the nozzle holder, ensuring that it
forms a seal against the nozzle holder rubber
washer.
2.1.6 The blast pot is now ready for operation
3.0 OPERATING INSTRUCTIONS
3.1 Blasting operating instructions
Blast pot operations
NOTE: CHECK WITH YOUR LOCAL
AUTHORITIES TO DETEMINE IF IT IS
PERMISSIBLE TO OPERATE A MANUALLY
CONTROLLED BLAST POT IN THE LOCAL AREA.
BP600-3
Figure A.
3.1.1 Ensure that the blast pot & compressed air
supply has been set up as detailed in section
2.0 of this manual.
3.1.2 Check that the main air supply ball valve (Figure
A. No.2) of the blast pot piping is fully closed
3.1.3 Check that the choke line ball valve is fully open
(Figure A. No.3)
3.1.4 Check that the blast pot exhaust ball valve is
fully closed (Figure A. No.1)
3.1.5 Fully close the abrasive metering ball valve
(Figure A. No.4) located on the bottom of the
blast pot by turning the control handle to a right
angle position.
3.1.6 Load the abrasive media into the blast pot by
pouring it in through the pop up valve opening
located on top of the blast pot. The blast pot
screen (where supplied) should be used to
prevent coarse debris and oversize particles
from entering the blast pot.
! WARNING! –DO NOT OVERFILL THE BLAST
POT. THE ABRASIVE LEVEL SHOULD REMAIN
BELOW THE BOTTOM OF THE POP UP VALVE
TO PREVENT PREMATURE WEAR TO THE
EXHAUST VALVE ASSEMBLY.
3.1.7 Check that all hose connections, fittings, safety
locking pins etc. are all secure and in the proper
location.
3.1.8 Start the air compressor, and allow the
compressor to reach the desired operating
pressure. Do not set the blast pressure below
345Kpa (50psi) as the blast system may not
operate correctly (this is to ensure that the pop
up valve will operate).
! WARNING! – DO NOT EXCEED THE
MAXIMUM OPERATING PRESSURE OF THE
BLAST POT AT ANY TIME AS THIS COULD
RESULT IN SERIOUS INJURY OR DEATH.
NOTE: THE SYSTEM IS NOW READY TO
OPERATE AND THE BLAST POT WILL
PRESSURIZE IF THE MAIN SUPPLY BALL VALVE
IS TURNED ON.
THE OPERATOR SHOULD WEAR APPROVED
SUPPLIED AIR RESPIRATORY EQUIPMENT (SAR)
BEFORE ACTIVATING THE BLASTING MACHINE.
3.1.9 Pick up the blast hose at the blast nozzle end,
and direct the blast nozzle at the surface/part
to be blasted.
3.1.10 When ready, the blast operator indicates to the
pot tender, who then closes the exhaust ball
valve (Figure A. No.1) and then opens the main
air supply ball valve (Figure A. No.2) which
pressurizes the blast pot and lifts the pop up
valve. Compressed air will only exit at the blast
nozzle.
! WARNING! - DO NOT OPEN THE MAIN AIR
SUPPLY BALL VALVE IF THE BLAST NOZZLE IS
NOT FIRMLY HELD BY THE OPERATOR.
UNSECURED BLAST HOSE WITH COMPRESSED
AIR FLOW WILL WHIP AND MAY CAUSE
SERIOUS INJURY OR DEATH.
! WARNING! – DO NOT EXCEED THE
MAXIMUM OPERATING PRESSURE OF THE
BLAST POT.
3.1.11 Once the blast pot is pressurized, check the
piping for air leaks. If leaks are found, close the
main supply air ball valve and open the exhaust
ball value. Shut down the compressor before
rectifying any air leaks.
3.1.12 If no leaks are found, slowly rotate the abrasive
metering ball valve handle (Figure A. No.4) from
the 90 degree closed position, until the desired
abrasive flow level is achieved. The optimum
abrasive flow level will vary depending on actual
operating conditions and the desired end result,
but as a general rule, the abrasive should
appear in the air stream as a fine mist. Once the
desired abrasive flow rate has been achieved,
the system is now set for ongoing blasting
operations.
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ZVP-PC-0154-00-R1
NOTE: FOR FINE ABRASIIVE, IT IS NECESSARY
TO SLIGHTLY CLOSE THE PUSHER LINE CHOKE
BALL VALVE TO INCREASE DIFFERENTIAL
PRESSURE TO ASSIST ABRASIVES FLOW
THROUGH THE ABRASIVE METERING VALVE.
! WARNING! – EXCCESSIVE THROTTLING OF
THE CHOKE VALVE WILL CAUSE HIGH WEAR
ON ABRASIVE METERING VALVE.
3.1.13 To stop blasting, the blast operator indicates to
the pot tender, who closes the main supply ball
valve (Figure A. No.2), and then quickly opens
the air exhaust valve (Figure A. No.1), which
depressurizes the blast pot and drops the pop
up valve.
3.2 Shutdown procedure
3.2.1 Close the main supply ball valve located on the
blast pot.
3.2.2 Opens the air exhaust ball valve (figure A. no.1),
which depressurizes the blast pot to release the
pop up valve.
Figure B.
3.2.3 Shut down the air compressor.
3.2.4 Cover the blast machine with the lid (where
supplied) and coil up and store the blast hose
and to prevent accidental damage.
4.0 MAINTENANCE
! WARNING! – THE COMPRESSED AIR
SOURCE MUST BE ISOLATED BEFORE
PERFORMING ANY MAINTENANCE WORK.
FAILURE TO DO SO MAY CAUSE SERIOUS
INJURY OR DEATH.
4.1 On a daily basis
4.1.1 If fitted, drain any water/moisture from the
moisture separator by opening the drain valve
located on the bottom of the water trap bowl.
Unscrew the retaining ring and remove the
water trap bowl. Check the filter element for
blockages and replace as required. Re-fit the
bowl and locking ring, and close the bowl drain
valve.
NOTE: IT IS ALWAYS GOOD TO ENSURE THE
INCOMING PRESSURIZED AIR IS EQUIPPED
WITH A DRYER SYSTEM TO ENSURE THE
INLET AIR IS DRY.
4.1.2 Inspect the blast hose for wear by feeling along
its full length for soft spots, which indicate wear,
and replace the hose as necessary.
4.1.3 Check all blast hose couplings are secure and
that all safety-locking pins are correctly in place.
4.1.4 Remove the safety locking pins and disconnect
the couplings by twisting the coupling counter
clockwise. Inspect the coupling gaskets for wear
and correct seating. Replace the gaskets as
required. Reconnect the coupling by engaging
the lugs with the pot coupling and twisting the
hose coupling until fully engaged, and then re-
fit the safety locking pins.
4.2 On a weekly basis
4.2.1 Remove the blast nozzle from the nozzle holder
by unscrewing the nozzle in a counter clockwise
direction, and inspect it for wear. Replace the
nozzle if when the internal diameter is worn by
1.5mm (1/16”) from its original size, or if the
liner is chipped or cracked.
4.2.2 Check the condition of the nozzle washer and
replace as required, then re-fit/replace the blast
nozzle by screwing it clockwise into the nozzle
holder until it is fully sealed against the nozzle
washer.
4.2.3 Check the condition of the nozzle holder, and
inspect for any cracks or signs of damage.
Replace if required as detailed in section 2.1.2.
4.3 On a monthly basis
4.3.1 Inspect the pop up valve located in the top of
the blast pot for wear in the form of cracks or
grooves (section 6.1.1. item1). If replacement is
required, remove the pot shell inspection cover
located on the side of the blast pot. Using a
suitable pipe wrench, unscrew the vertical pipe
section which houses the pop up valve, and
remove both the pipe section and pop up valve
through the inspection opening. Installation of
the new pop up valve is a reversal of the
removal procedure. Ensure that the pop up valve
is positioned directly below the top opening for
correct sealing.
Figure C.
4.3.2 Check and inspect the pop up valve seating ring
for wear (section 6.1.1. item2). If replacement is
necessary, use a large screw driver or similar
tool to pry the seating ring out of the seat.
When re -fitting the new seating ring, ensure
that it is correctly seated within the seating ring
housing.
Figure D.
4.3.3 Inspect the blast pot exhaust muffler and
exhaust line (if fitted) for wear or blockages,
replace the worn or blocked muffler and
exhaust line as necessary.

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ZVP-PC-0154-00-R1
5.0 TROUBLE SHOOTING GUIDE
Item Problem Possible Cause Corrective Action
1 Blast pot will not
pressurize
No / inadequate compressed air
supply
Check that air compressor is
operational. Ensure air output and
supply hose size is correct.
Main supply ball valve (Figure A. No.2)
is closed Open ball valve
Pop up valve / seating ring worn or
damaged Inspect & replace as required
Exhaust ball valve open Close exhaust ball valve
2
No air and/or
abrasive flow
from nozzle
Blast nozzle blocked
Depressurize system & remove nozzle
from its holder
Check & clear any possible blockage.
Re-fit nozzle
Pusher line choke valve fully closed Open and adjust the choke valve as
necessary.
Abrasive ball valve (Figure A. No. 4)
fully closed
Open and adjust abrasive ball valve as
required
Pop up valve or seating ring worn or
damaged Inspect and replace as required
Insufficient abrasive in blast pot Refill with abrasive as required
Excessive dust and fines in abrasive Drain abrasive from blast pot and refill
with clean abrasive
Damp or wet abrasive in blast pot Drain abrasive from blast pot and refill
with clean abrasive
3 Intermittent
abrasive flow
Excessive dust and fines in abrasive Drain abrasive from blast pot and refill
with clean abrasive
Insufficient abrasive in blast pot Refill with abrasive as required
Damp or wet abrasive in blast pot Drain abrasive from blast pot and refill
with clean abrasive
Excessive abrasive
Check and adjust air pressure as
required.
Compressed air supply pressure too
low
4 Excessive abrasive
flow
Abrasive ball valve (Figure A. No.4)
fully opened
Adjust abrasive ball valve (Figure A. No.
4) as required
Pusher line choke valve fully closed Open & adjust choke valve as required
5 Excessive wear on
blast hose
Blast hose kinked or coiled Keep blast hose as straight as possible
without being coiled.
Blast nozzle excessively worn Check the internal diameter of blast
nozzle and replace if necessary.

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6.0 ASSEMBLIES, PARTS LISTING & EXPLODED VIEW
6.1 PanBlastTM BP600-3 Blast Pot Assembly
Stock Code Description Dry Weight Abrasive Capacity Piping Size
BEP-PS-0073-00 BP600-3/AU/NZ Manual Ball Valve 195kg(430lbs) 200litres (6ft3) 32mm (1 1/4”)
6.1.1 PanBlastTM BP600-3 Blast Pot Parts Listing
Item Stock Code Description Qty
1 BAC-BF-PB-0012 Pop Up Valve - Stem Type 1
2 BAC-BF-PB-0013 Pop Up Valve Seating Ring 1
3 BAC-HC-0080-00 STC-1 Steel Threaded Blast Coupling 1
4 BAC-PF-PB-0006 32mm (1-1/4") Ball Valve 3
5 BAC-PF-PB-0003 25mm (1") Ball Valve 1
6 BAC-PF-0274-00 1/2" BSP - 125 PSI Pressure Relief Valve 1
7 BAC-PF-PB-0031 6mm (1/4") Pressure Gauge - Rear Entry 1
8 YAC-FN-PB-0244 Hose Clamp 2
9 YAC-PF-PB-0184 KC Nipple 2
10 YAC-BF-PB-0046 Hose-Air/Water Delivery 32mmIDx45mmOD 1 MTR
11 YAC-BF-0231-00 Blast Pot-H/Hole 192x144-Sealing Gasket 1
6.1.2 PanBlastTM BP600-3 Blast Pot Exploded View

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ZVP-PC-0154-00-R1
6.2 PanBlastTM BP600-3 Blast Pot Assembly
6.2.1 PanBlastTM BP600-3 Blast Pot Parts Listing
Item Stock Code Description Qty
1 BAC-BF-PB-0012 Pop Up Valve - Stem Type 1
2 BAC-BF-PB-0013 Pop Up Valve Seating Ring 1
3 BAC-HC-PB-0009 NTC-1 Nylon Threaded Pot Coupling 1
4 BAC-PF-PB-0006 32mm (1-1/4") Ball Valve 3
5 BAC-PF-PB-0003 25mm (1") Ball Valve 1
6 BAC-PF-0274-00 1/2" BSP - 125 PSI Pressure Relief Valve 1
7 BAC-PF-PB-0031 6mm (1/4") Pressure Gauge - Rear Entry 1
8 YAC-FN-PB-0244 Hose Clamp 2
9 YAC-PF-PB-0184 KC Nipple 2
10 YAC-BF-PB-0046 Hose-Air/Water Delivery 32mmIDx45mmOD 0.75 MTR
11 YAC-BF-0231-00 Blast Pot-H/Hole 192x144-Sealing Gasket 1
6.2.2 PanBlastTM BP600-3 Blast Pot Exploded View
Stock Code Description Dry Weight Abrasive Capacity Piping Size
BEP-PS-0052-00 BP600-3/MY Manual Ball Valve 195kg(430lbs)
200litres (6ft3) 32mm (1 1/4”)
BEP-PS-0053-00 BP600-3/SG Manual Ball Valve