Praxair 1264 User manual

Revision M Issued: 04/16
Model 1264
Powder Feeder
Operator’s Manual
Manual Part Number: 5006267

EC Declaration of Conformity
We, Praxair Surface Technologies, 146 Pembroke Road, Concord, NH 03301
USA, declare under sole responsibility that the Model 1264 Powder Feeder to
which this declaration relates is in conformity with the relevant provisions of the
following standard(s) or other document(s):
Applied Directive(s): Low Voltage 2006/95/EC
EMC 2004/108/EC
Pressure Equipment 97/23/EC
Standard(s): EN 60204-1
EN 61000-6-4
EN 61000-6-2
We hereby declare that the equipment specified above conforms to the above
directive(s) and standard(s).
Signature:
Full Name:
Andrew Bolduc
Position:
Engineering Manager
Praxair Surface Technologies, Inc.
146 Pembroke Road
Concord, NH 03301
[phone] phone
[phone] fax

DISCLAIMERS
All information referred to and/or included in this manual is current as of the original issue date of
this manual. Praxair Surface Technologies, Inc. makes no warranty or representation with respect to
the accuracy of the information contained therein nor with respect to the suitability of the use of
such information outside Praxair Surface Technologies, neither does Praxair Surface Technologies
assume responsibility for any injury or damage which may result, directly or indirectly, from the
use of such information.
The information contained herein is offered for use by technically qualified personnel at their
discretion and risk without warranty of any kind. Praxair Surface Technologies is constantly
improving its products, and specifications are subject to change without notice.
This manual could include technical inaccuracies or typographical errors. Changes are made
periodically to the information herein; these changes will be incorporated in subsequent revisions of
the manual. Praxair Surface Technologies reserves the right to make improvements and/or changes
to the product(s) and/or programs described in this manual at any time and without notice.
Illustrations are meant to be representative of, but not exact duplicates of, existing equipment.
BUSINESS CONFIDENTIAL
THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION
OF PRAXAIR SURFACE TECHNOLOGIES. THIS INFORMATION IS PROVIDED IN
CONFIDENCE SOLELY FOR USE WITH OUR MODEL 1264 POWDER FEEDER. THIS
MANUAL MAY NOT BE REPRODUCED IN ANY FORM OR ITS CONTENTS
DISCLOSED TO THIRD PARTIES WITHOUT THE PRIOR WRITTEN CONSENT OF
PRAXAIR SURFACE TECHNOLOGIES.
TRADEMARK INFORMATION
Praxair and the Flowing Airstream design are trademarks or registered trademarks of Praxair
Technology, Inc. in the United States and other countries.
TAFA and the TAFA Flame design are trademarks or registered trademarks of Praxair S.T.
Technology, Inc. in the United States and other countries.
Other trademarks used herein are trademarks or registered trademarks of their respective owners.
Praxair Surface Technologies, Inc.
Printed in the United States of America. Copyright © 2015
Praxair S.T. Technology, Inc.

Model 1264 Powder Feeder
Operator’s Manual
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Safety First Read This Before Using
Thermal Spray Equipment
WARNING
Read and understand operator’s manual before using this machine. Failure
to follow operating instructions could result in injury or damage to
equipment.
Thermal spraying is powerful technology. Do not use equipment
carelessly or without observing safe practices. Be safe!
Learn the recommended procedures and standards.
Failure to follow recommended procedures and standards
can result in severe injury to people and damage to equipment.
Who should use Thermal Spray Equipment?
Use the equipment only if you have been trained fully in safely using it.
Do not allow untrained persons to install, operate, or maintain the
equipment.
Understand what to do before you do it!
Make sure that you have read and understand the contents of this manual -
especially the safety guidelines and operating procedures - before
installing, operating, or maintaining this equipment. Contact a Factory
Representative if you do not fully understand any guidelines or
instructions.

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Operator’s Manual
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Generic Thermal Spray Process
Sources of Information
To work safely with thermal spray equipment, become familiar with these
items:
This manual and related documentation, especially:
-Safe practices and safety guidelines described in section 1 and in
highlighted paragraphs throughout this guide
-Operating instructions (see section 4)
Technical bulletins included with or referred to in this manual. This
includes industry publications that contain standards that may apply to
your work. (See page vi of this guide for a list of industry
publications.)
Labels, tags, other instructions, and warnings that come with or are
attached to the equipment
Guidelines and practices your specific site has established as standard
About This Manual
This manual presents information about setting up, operating, maintaining,
and troubleshooting your equipment.

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Operator’s Manual
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Conventions
Throughout this manual, certain words and symbols are used to draw your
attention to important information. These symbols and words have the
following meaning:
Praxair Surface
Technologies
RECOMMENDS
A procedure or setting that will produce optimum results
Information that can help to operate the equipment more effectively.
Refer to the manual before doing any maintenance.
Wear respirator.
Risk of eye injury. Eye protection required.
Wear opaque eye protection.
Wear protective clothing, gloves.
Wear hearing protection.
Pressure Relief
WARNING
PERSONAL INJURY HAZARD:
Use caution when handling the powder feeder, feed lines and
fittings. There is a possibility of static electricity discharge from the
powder feed system which could result in significant discomfort or
injury.

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HAZARD
Hazards that can result in minor or major damage to equipment,
bodily injury to people, and how to prevent such hazards.
EXPLOSION HAZARD
ELECTRIC SHOCK HAZARD
FIRE HAZARD
HIGH TEMPERATURE HAZARD
ELECTROMAGNETIC FIELDS HAZARD
LIGHT EMISSION HAZARD
People with Heart Pacemakers Not Allowed

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Operator’s Manual
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Related Publications
Information that can help
OSHA (Occupational Safety and Health Administration) establishes
mandatory federal safety regulations. For information about the
regulations, refer to OSHA Standards, Code of Federal Regulations,
Title 29, Part 1910.
Handling compressed gas is among the safety hazards associated with
thermal spraying. ANSI/AWS Z49.1, Safety in Welding and Cutting
and the Williams-Steiger Occupational Safety and Health Act of 1970
(84 Stat. 1943) cover safe handling of compressed gases. More recently,
the Resource Conservation and Recovery Act (RCRA), dealing with the
disposal of toxic wastes, potentially affects the thermal spray industry.
Occupational Safety and Health Act Standards (29CFR 1910),
available from the Superintendent of Documents, U.S. Government
Printing Office.
Ventilation Control of Grinding, Polishing and Buffing of Metals,
ANSI Z43.1, available from the American National Standards Institute.
Safety in Welding and Cutting, AWS/ANSI Z49.1, available from the
American Welding Society.
Environmental, Health, and Safety Guidelines, available from TSS an
affiliate society of ASM International (ASM TSS).
Standard Practices for Respiratory Protection, ANSI Z88.2, available
from the American National Standards Institute.
Safety Requirements for Industrial Hand Protection, ANSI Z89.1,
available from the American National Standards Institute.
National Electrical Code, NFPA 70-2008, available from the National
Fire Protection Association, updated annually.
Safe Handling of Compressed Gases, CGA Pamphlet P-1, available
from the Compressed Gas Association.
Oxygen, CGA Pamphlet G-4, available from the Compressed Gas
Association.

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NFPA 50 Bulk Oxygen Systems at Consumer Sites, available from the
National Fire Protection Association.
NFPA 55 Compressed & Liquefied Gases in Portable Cylinders,
available from the National Fire Protection Association.
NFPA 30 Flammable and Combustible Liquids Code, available from
the National Fire Protection Association.
Recommended Safe Practices for the Preparation for Welding and
Cutting of Containers That Have Held Hazardous Substances,
ANSI/AWS F3.1, available from the American Welding Society.
Safety Release Device Standards - Cylinders for Compressed Gases,
CGA Pamphlet S1.1, available from the Compressed Gas Association.
Standard for Gaseous Hydrogen at Consumer Sites, CGA Pamphlet
G5.1, available from the Compress Gas Association.
Power Piping, ANSI B31.1, available from the American National
Standards Institute.
Acetylene, CGA Pamphlet G-1, available from the Compressed Gas
Association.
Oxygen-Fuel Gas Systems for Welding and Cutting, NFPA 51,
available from the National Fire Protection Association.
Standard for Fire Prevention in Use of Cutting and Welding
Processes, NFPA 51B, available from the National Fire Protection
Association.
Standard for the Storage and Handling of Liquefied Petroleum Gases,
ANSI/NFPA 58, available from the National Fire Protection Association.
Industrial Ventilation: A Manual of Recommended Practice ACGIH
(25th Ed., 2004)

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Table of Contents
Read This Before Using Thermal Spray Equipment................................................................iii
Section 1 Safety Guidelines....................................................................................................1
1.1 Reminder: Safety First!..........................................................................................................1
1.2 General Guidelines.................................................................................................................2
1.3 Fire Protection and Prevention ..............................................................................................2
1.3.1 Keep Work Areas Clean ..........................................................................................2
1.3.2 High Temperatures...................................................................................................2
1.3.3 Hazardous Materials ................................................................................................3
1.4 Safe Operating Conditions .....................................................................................................3
1.4.1 Compressed Gas Cylinders......................................................................................3
1.4.2 Flow Meters.............................................................................................................4
1.4.3 Compressed Air .......................................................................................................5
1.4.4 Flame Spray and HVOF Equipment ........................................................................5
1.4.5 Plasma and Arc Spray Equipment............................................................................6
1.4.6 Abrasive Blast Machine...........................................................................................7
1.4.7 Handling and Manipulating Equipment...................................................................7
1.5 Protecting Workers.................................................................................................................8
1.5.1 Eye Protection..........................................................................................................8
1.5.2 Respiratory Protection..............................................................................................9
1.5.3 Noise Protection.....................................................................................................10
1.5.3.1 Noise and Noise Level .........................................................................10
1.5.3.2 Noise Duration.....................................................................................11
1.5.3.3 Hearing Protection ...............................................................................12
1.5.4 Protective Clothing ................................................................................................14
1.5.5 Confined Spaces.....................................................................................................15
1.5.5.1 Rapid Emergency Exit .........................................................................15
1.5.5.2 Factors to Consider ..............................................................................15
1.6 Toxic Material......................................................................................................................18
1.6.1 Beryllium and Lead................................................................................................18
1.6.2 Cadmium................................................................................................................18
1.6.3 Cobalt, Chromium, and Tellurium.........................................................................18
1.6.4 Tin and Zinc...........................................................................................................19
1.6.5 Solvents..................................................................................................................19
1.6.6 Threshold Limit Values .........................................................................................19
1.7 Safety Standards...................................................................................................................20
Section 2 Equipment Description........................................................................................21
2.1 Specifications.......................................................................................................................21
2.2 Equipment Description.........................................................................................................21
2.3 Options.................................................................................................................................22
Section 3 Installation............................................................................................................25
3.1 Unpacking/Moving...............................................................................................................25
3.2 Powder Feeder Installation...................................................................................................26
3.2.1 Installation of Plasma/HVOF Feeder ..........................................................................26
3.2.2 Installation of HP/HVOF Feeder with Pinch Valves...................................................28

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Section 4 Operation..............................................................................................................31
4.1 Powder Wheel Start/Stop Switch .........................................................................................32
4.2 Powder Feed Rate Control Dial (RPM)................................................................................32
4.3 Reset PM Hours Function ....................................................................................................32
A. Preventative Maintenance Time Accumulator ................................................................32
B. Total Run Time................................................................................................................33
4.4 Heater Blanket On/Off Switch .............................................................................................33
4.5 Mode Switches.....................................................................................................................33
A. Plasma Pressurization Mode............................................................................................34
B. HVOF Pressurization Mode.............................................................................................34
C. Local Mode......................................................................................................................34
D. Remote Mode..................................................................................................................34
4.6 Canister Clean Switch..........................................................................................................35
4.7 Remote Control Options.......................................................................................................35
A. Remote On/Off Control...................................................................................................35
B. Remote RPM Control ......................................................................................................36
4.8 General Operation Notes......................................................................................................39
4.9 Feeder Operation..................................................................................................................40
4.10 Basic Powder Feeder Cleaning.............................................................................................41
4.11 Thorough Powder Feeder Cleaning......................................................................................43
4.12 Emergency Shutdown...........................................................................................................47
Section 5 Maintenance & Troubleshooting........................................................................49
5.1 Routine Maintenance............................................................................................................49
A. Resetting Preventative Maintenance Time Accumulator ................................................50
B. O-Ring/Seal Replacement ...............................................................................................51
C. Checking Seal Integrity ...................................................................................................55
D. Gear Motor Brush Replacement......................................................................................56
E. Verification......................................................................................................................57
F. Powder Feeder RPM Fluctuations....................................................................................57
5.2 Troubleshooting Chart .........................................................................................................57
Figure 5-4 Electrical Schematic (P/N 5006802)...................................................................59
Figure 5-5 Estimated Feed Rate Chart for Standard Wheel .................................................60
Figure 5-6 Estimated Feed Rate Chart for Fine Wheel ........................................................61
Figure 5-7 Estimated Feed Rate Chart for High-Volume Wheel .........................................62
Figure 5-8 Estimated Feed Rate Chart for 120-Hole Wheel ................................................63
Figure 5-9 Estimated Feed Rate Chart for 240-Hole Wheel ................................................64
Figure 5-10 Estimated Feed Rate Chart for 320-Hole Wheel ..............................................65
Section 6 Parts List...............................................................................................................67
Figure 6-1 1264 Drawing Index......................................................................................................67
Figure 6-2 601195 1264 Hopper Assembly....................................................................................68
601195 1264 Hopper Assembly Bill of Material............................................................................69
Figure 6-3 1264 Chassis Exploded View, 1264 Chassis Sheet 1....................................................70
Figure 6-4 1264 Chassis Exploded View, 1264 Chassis Sheet 2....................................................71
Figure 6-5 1264 Chassis Exploded View, 1264 Chassis Sheet 3....................................................72
1264 Chassis Bill of Material..........................................................................................................73
Figure 6-6 601163 Pinch Valve Kit Option....................................................................................76
601163 Pinch Valve Kit Option Bill of Material............................................................................77

Model 1264 Powder Feeder
Operator’s Manual
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Section 1
Safety Guidelines
This section covers potential hazards and safety issues associated with
thermal spraying, preparing for its use, and its finishing processes.
Subjects include:
•Fire prevention and protection
•Safe operating conditions
•Flame spray and HVOF equipment
•Plasma and arc equipment
•Abrasive blast machines
•Safe operation of the equipment
•Worker’s protection
•Ventilation
•Toxic material handling
•Relevant safety standards
1.1 Reminder: Safety First!
Thermal spraying equipment is very powerful. Do not use equipment
carelessly or without observing safe practices. Be safe! Learn the
recommended procedures and standards. Failure to follow
recommended procedures and standards can result in severe damage to
equipment and injury to people.
Use the equipment only if you have been trained fully in its safe
operation. Do not allow untrained persons to install, operate, maintain,
or troubleshoot the equipment.
Make sure that you have read and understand the contents of this
manual - especially the safety guidelines and operating procedures -
before installing, operating, or maintaining this equipment. Contact a
Factory Representative if you do not fully understand any guidelines or
instructions.
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1.2 General Guidelines
All persons concerned with thermal spraying must know and understand
these safe practices and the safety regulations contained in established
standards. Pertinent established standards are listed in "Related
Publications" on page vii.
Information presented in this manual and on various labels, tags, and
plates on the unit pertains to equipment design, installation, operation,
maintenance, and troubleshooting that should be read, understood, and
followed for the safe and effective use of this equipment.
The installation, operation, maintenance, and troubleshooting of thermal
spray equipment requires practices and procedures that ensure personal
safety and the safety of others. Therefore, this equipment is to be
installed, operated, and maintained by qualified persons as specified in this
manual and in accordance with all applicable codes such as, but not
limited to, those listed in section 1, and the corresponding sections of the
manual. You should thoroughly understand and comply with local, state,
and federal (OSHA) health standards, especially when handling toxic
materials.
1.3 Fire Protection and Prevention
1.3.1 Work Areas
Keep the work area clean! Avoid accumulating metal dusts. Inspect
rafters, tops of booths, and floor cracks for dust accumulation.
NEVER store paper, wood, oily rags, or cleaning solvents within the
spray room or enclosure.
1.3.2 High Temperatures
Thermal spraying operations generate extremely high temperatures.
NEVER point thermal spray equipment at any person or flammable
material.
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1.3.3 Hazardous Materials
Toxic Wastes
Preparations for thermal spraying, the process itself, or subsequent
finishing operations may generate toxic materials. Dispose of them
according to the EPA Resource Conservation and Recovery Act
(RCRA).
Flammable Solvents and Sealer Bases
Certain de-greasing solvents and sealer bases are flammable and require
special use, handling, and storage precautions in and around the thermal
spray area.
Metal Dusts and Powders
Treat airborne metal dusts, finely divided solids, or accum
ulations as
explosives. Minimize the danger from dust explosions by providing
adequate ventilation in spray booths. Install a cartridge-type dry dust
collection system to collect spray dust.
1.4 Safe Operating Conditions
1.4.1 Compressed Gas Cylinders
Always comply with local, state, municipal, and federal regulations
regarding compressed gas cylinder storage and follow recommendations
in ANSI/AWS Z49.1, Safety in Welding and Cutting; CGA Pamphlet
P-1, Safe Handling of Compressed Gases; NFPA 55, Compressed &
Liquefied Gases in Portable Cylinders; NFPA 51, Oxygen-Fuel Gas
Systems in Welding and Cutting; and NFPA 51B Standard for Fire
Prevention in the Use of Cutting & Welding Processes. Improper
storage, handling, and use of gas cylinders Creates A Safety Hazard. If
the site plan includes manifolding cylinders to permit longer spray times
before changeover, follow ANSI/AWS Z49.1 recommendations in
designing the plan.
NEVER use oil or grease on oxygen equipment. Use ONLY special
oxidation- resistant lubricants. Consult the equipment manufacturers or a
qualified dealer for more information.
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Be sure the work area is adequately ventilated before opening any gas
valves. Drain the regulator of gas and release the regulator adjusting
screw before SLOWLY opening the cylinder valves. ALWAYS stand
away from the direction of force when opening cylinder valves.
Install pressure reducing regulators in accordance with ANSI/AWS Z49.1.
Use only the appropriate regulator for each gas cylinder: USE ONLY
ACETYLENE REGULATORS ON ACETYLENE TANKS OR
MANIFOLD SYSTEMS. Always use the correct size wrench to connect
the regulator to the cylinder valve outlet; NEVER force or overtighten a
connection.
NEVER use oil or grease on a regulator.
1.4.2 Flow Meters
Install and use flow meters in accordance with ANSI/AWS Z49.1. Avoid
unsafe operating conditions and ensure proper flame balance by installing
backflow prevention devices in conjunction with the flow meters. Place a
protective shield on flow meters with glass tubes.
Install and use hose and hose connections according to ANSI/AWS Z49.1
and the Specification for Rubber Welding Hose published by the
Rubber Manufacturer’s Association and the CGA. Handle hoses carefully
to avoid damage. Use hoses only in the applications for which they are
designed. Blow out hoses to remove any dust. Avoid any ignition sources.
Turn regulator adjusting screws slowly to prevent surges that may crack or
burst flow meter tubes. Overtightening can collapse the nipple nose, so
NEVER OVERTIGHTEN the connecting nuts on pressure reducing
regulators and flow meters. If a fitting does not seal without undue force,
replace it.
NEVER use a flame to check for gas leaks. Use soapy water to check all
hose connections for leaks. Soapy water provides a safer, more sensitive
test.
If any connections leak, depressurize, open the connection, clean the
sealing surfaces and threads, re-assemble, pressurize, and test for leaks. If
a leak persists, depressurize the system.
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EXPLOSION HAZARD:
NEVER USE LEAKING THERMAL SPRAY EQUIPMENT.
Place a “Danger Do Not Operate” tag on the defective equipment to
alert others to the unsafe condition.
Obstructed gas lines caused by defective hoses, collapsed hose stems, or
dirt in the gun head gas passages or nozzle jets require excessive gas
pressure to obtain proper gas flow.
If required oxygen and fuel gas pressure are more than 3 psi (0.2 bar) over
the recommended pressure, check for a fouled nozzle or incorrect air cap.
Low pressures often indicate a serious leak. Shut down the equipment and
correct the condition before restarting the system.
EXPLOSION HAZARD:
Acetylene pressures exceeding 15 psi (1.03 bar) may cause the gas to
detonate. If this pressure of 15 psi (1.03 bar) is insufficient, use another
fuel gas.
1.4.3 Compressed Air
Always refer to gases by their proper names to avoid confusion.
Never use compressed air, oxygen, or fuel gas to clean clothing.
For thermal spraying or blasting operations, use compressed air only at
recommended pressures. Keep the air line free of oil and moisture.
Consult an equipment dealer for filter and after-cooler recommendations.
1.4.4 Flame Spray and HVOF Equipment
Thoroughly read and understand this manual and familiarize all operators
with gun operation before lighting the gun. Maintain guns according to
recommendations.
PERSONAL INJURY (BURN) HAZARD:
Using a match to light a flame spraying gun can result in serious injury.
Use a friction lighter, pilot light, or arc ignition instead.
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Properly seating and lubricating the gun's oxygen, fuel gas, and
compressed air valves helps the gun operate freely and shut off
completely.
Extinguish gun backfires as quickly as possible.
Determine the cause of gun backfires or blowouts BEFORE relighting.
When you have completed spray operations, when you are shutting down
the equipment, or when you leave the equipment unattended, release all
gas pressure from the regulators and hoses.
EXPLOSION OR FIRE HAZARD:
NEVER hang a flame spraying gun or its hoses on regulators or cylinder
valves.
1.4.5 Plasma and Arc Spray Equipment
Plasma and arc spray equipment differ from flame and HVOF equipment.
They use high voltages and amperages that represent an electrical hazard.
Train operators how to use the equipment safely before they actually use
it. Specifically, ensure that operators know and understand all the
operating and safety recommendations in the operator manuals. Always
observe standard safety precautions for electrical equipment and operate in
accordance with ANSI/AWS Z49.1.
Frequently clean arc guns and power supplies to prevent metal dust
accumulation that causes electrical short circuits. Properly insulate or
ground the wire feed units used with the arc spray equipment. If the gun is
suspended, insulate or ground the suspension hook. Ground or insulate all
exposed plasma gun electrodes and cable connections. Interconnect all
ground cables.
Periodically inspect cables, insulation, hoses, and gas lines. All
pushbuttons, pilot lights, plugs, and cables should be intact and meet
ANSI/NFPA 70-2011,National Electrical Code standards. Repair or
replace faulty equipment at once. Never adjust, clean, or repair any part of
the power supply, console, or gun without first disengaging the entire
system, including the power supply.
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Avoid contact between any ungrounded portion of the plasma or arc gun
and the spray booth or chamber. Electrically isolate plasma guns and
nozzles from support brackets to prevent stray high frequency current
from damaging other electrical equipment and controls.
1.4.6 Abrasive Blast Machine
Maintain and inspect abrasive blast machines according to manufacturer's
instructions. Remove and repair or replace worn parts as needed. Do not
exceed recommended air pressure in the blast tank.
Keep blast hoses as straight as possible between the blast machine and
blasting area. Sharp hose bends cause excessive friction and wear that can
lead to a blowout at those points. If hoses must be curved around an
object, use long radius curves. Store blast hoses in cool, dry areas.
Be sure blast hose controls function properly. They should require
continuous pressure on the activating lever for operation. Releasing the
lever should cause the system to shut off (dead man control).
PERSONAL INJURY:
NEVER point a blast nozzle at a person.
Most blasting operations require respiratory protection for the operator.
Select, operate, and maintain the protective device according to ANSI
Z88.2, Standard Practices for Respiratory Protection, described in
section 1.5.2.
1.4.7 Handling and Manipulating Equipment
Most thermal spray and blasting applications require rotation or other
manipulation of the part being worked on. Some handling equipment can
impart high rotational speeds to parts being coated. Affix and balance
parts when necessary. Provide protection for the operator in case a
rotating part becomes airborne. Never leave operating equipment
unattended.
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1.5 Protecting Workers
The general requirements for the protection of thermal spraying operators
and welders are the same as those published in ANSI/AWS Z49.1, Safety
in Welding and Cutting; ANSI Z87.1, Standard Practices for
Occupational and Educational Eye and Face Protection; ANSI Z88.2,
Standard Practices for Respiratory Protection; and ANSI Z89.1,
Standard Practices for Industrial Head Protection with Low Voltage
Hazards.
1.5.1 Eye Protection
Spraying and blasting operations require eye protection in the form of
helmets, hand shields, face shields, or goggles. See ANSI Z87.1 and
Z89.2 for recommendations. Operators MUST use protection against
infrared and ultraviolet radiation and flying particles. Provide all helpers
and adjacent operators with suitable eye protection as well. Equip the eye
protection with a suitable filter plate to protect against ultraviolet, infrared,
and intense visible light radiation (see Table 1-1).
Table 1-1
Eye Protection
Operation
Required Type of
Eye Protection
Wire Flame Spraying (except Molybdenum)
Shades 2-4
Molybdenum Wire Spraying
Shades 3-6
Flame Spraying of Metal Powder
Shades 3-6
Flame Spraying of Exothermic Ceramic Powder or Rod
Shades 4-8
Plasma and Arc Spraying
Shades 9-12
Arc Bonding
Shades 5-6
Fusing Operations
Shades 4-6
In thermal spray operations where additional respiratory protection is not
required, operators may wear eye protecting goggles alone. The goggles
should have indirect ventilating fins to reduce fogging and eliminate
danger from flying particles. In plasma spray operations, replace the
goggles with helmets or hand shields that provide face, chin, and neck
protection from infrared and ultraviolet radiation.
When blasting, use face shields or helmets equipped with dust hoods to
protect eyes, face, chin, and neck. Provide respiratory protection, as well
as other protection discussed in the following paragraphs.
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1.5.2 Respiratory Protection
Respiratory protection is necessary for most spray and blast operations.
Selection of device is determined, in accordance with ANSI Z88.2, by the
nature, type, and magnitude of the fume and gas involved. Select only
devices approved by the U.S. Bureau of Mines, National Institute of
Occupational Safety and Health (NIOSH), or an other approved
authority. Suggested devices for typical thermal spraying and blasting
operations include:
Blasting in the open:use a mechanical filter respirator with a face
shield and dust hood or a self-contained breathing apparatus.
Thermal spraying in confined or semi-confined spaces: use an air line
respirator. Use a device similar to the one described below for abrasive
blasting.
Abrasive blasting in confined or enclosed spaces: use a continuous
flow air line respirator consisting of a continuous flow air line respirator,
a full face piece or helmet, and dust hood sufficient to protect the head and
neck from rebounding abrasive material. Minimum air flow to the
respirator should be 4 CFM (113.3 L/minute) at the face piece and 6 CFM
(170 L/minute) entering the helmet or hood. Fresh air blowers are
preferred to compressed air as an air source of respirator air. If adequate
ventilation is not provided, use an in-line vortex cooler when possible for
operator comfort. Filter the air supply line to remove objectionable odors,
oil or water mist (or both), and rust particles from the air. Locate the air
intake to ensure the respirator receives clean, dry air (CDA). If gaseous
air contaminants such as carbon monoxide are possible, use a separate air
purifier. Grade D or better compressed air is considered breathable.
Thermal spraying in an open or a well-ventilated work area: additional
respiratory protection may not be necessary. In borderline cases, use
approved mechanical filter respirators for protection against dust and
metal fumes. Borderline cases are those that consist of light work or short
duration with nontoxic materials, but with some dust exposure.
Continuous flow air line respirators are adequate for thermal spraying
operations involving most commonly used materials. If the respirator air
supply fails and the contaminant in the space is not immediately harmful
to health, the operator may stop operations, remove the supply line, and
return to breathable air.
Issued: 10/11 Page 9