PRODUCT OPERATING MANUAL

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1 PRODUCT OPERATING MANUAL PANBLAST TM CONEBLAST ½ INTERNAL PIPE TOOL Manual Number: ZVP PC

2 SECTION 1. GENERAL INFORMATION 2. INTRODUCTION 3. INITIAL SETUP INSTRUCTIONS 4. OPERATING INSTRUCTIONS 5. MAINTENANCE 6. TROUBLE SHOOTING GUIDE 7. ASSEMBLIES, PARTS LISTING & EXPLODED VIEW

3 1.0 GENERAL INFORMATION 1.1 Panblast Notice to Purchasers and Users 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 It is the responsibility of the user to: - Determine if the equipment and abrasive media are 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 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 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 (SAR) equipment by blast operators and all personnel within the work site area 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 Approved safety eyewear, hearing and footwear protection should be worn at all times by the operator and any personnel in the immediate area that may be exposed to any hazards generated by the abrasive blasting process 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 Any work performed on any electrical wiring or components must only be carried out by suitably qualified and registered electrical personnel Under no circumstances should any safety interlocks/lockouts or features be altered or disabled in any way All equipment must be isolated from the compressed air supply and electrical power prior to any service or maintenance work being carried out 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 Any modification of the equipment/components or use of non genuine PanBlast replacement parts will void warranty Always check the Material Safety Data Sheet (MSDS) on the abrasive media being used, ensure that the abrasive media is free of harmful substances, in particular, free silica, cyanide, arsenic or lead Test the surface which is to be blasted for harmful substances, taking the appropriate measures to ensure the safety of all personnel 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, 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. 2.0 INTRODUCTION 2.1 The PanBlast TM ConeBlast ½ Internal Pipe Blasting Tool is designed to clean the internal surfaces of pipes from 50mm (2 ) to 305mm (12 ) ID.. The tool is connected to a pipe lance that is coupled to a standard blast hose in place of the blast nozzle. When operating the ConeBlast ½ propels abrasive media via the 12mm (1/2 ) internal blast nozzle to the tungsten carbide deflection tip. The tungsten carbide deflection tip projects the abrasive media in a 360 degree blast pattern to the inner pipe wall creating the abrasive blast cleaning process. Refer to the application table (2.3) below for the centering carriage assemblies and air volume requirements to suit various applications. 2.2 Application Table Pipe ID Carriage Type Button Length 50mm (2 ) Tool only / 75mm (3 ) 88mm (3-1/2 ) 100mm (4 ) 112mm (4-1/2 ) 125mm (5 ) 125mm 305mm (5 ) - (12 ) Tool with Collars Collar & Button Set Collar & Button Set Collar & Button Set Collar & Button Set Scissor Carriage / 7.9mm (5/16 ) 14.3mm (9/16 ) 20.6mm (13/16 ) 27mm (1-1/16 ) Compressed Air Volume Note: Above air consumption volume requirements are based on the 12mm (1/2 ) blasting nozzle being in new condition. Provisions in surplus air volume must be taken in to consideration for nozzle wear. The internal blast nozzle is considered worn out / - 1

4 when it has worn approximately 3mm (1/16 ) from its original size. Abrasive Recommendations: The selection of abrasive media generally dictates the surface profile and abrasive blast cleaning rates. The abrasives with larger particle size and high bulk density will usually achieve a greater surface profile, whilst small light density abrasives will clean faster. The ConeBlast ½ assembly is designed to run abrasive media sizes of 25 mesh and finer. Note: Soft abrasive media types will provide poor results due to the high break-up factor after impacting against the deflection tip. Note: The use of hard abrasives such as silicon carbide/aluminium oxide will produce accelerated wear of the ConeBlast ½ Deflection Tip. If hard abrasive type must be utilized it is recommended to upgrade the deflection tip to the PanBlast TM Boron Carbide Deflection Tip stock code: YAC-BA-PB PREPARATION FOR OPERATION! WARNING! THE SYSTEM MUST BE IN SHUT DOWN MODE AND THE COMPRESSED AIR DISCONNECTED BEFORE PERFORMING ANY INSTALLATION WORK. FAILURE TO DO SO MAY RESULT IN PREMATURE ACTIVATION OF THE SYSTEM THAT MAY CAUSE SERIOUS INJURY OR DEATH. 3.1 Pipe Lance (Client Supply) The pipe lance is a length of 32mm (1-1/4 ) pipe that is positioned between the blasting hose and the ConeBlast ½ Tool. It is always recommended that the pipe lance length is the same length as the pipes that are being abrasive blast cleaned. 3.2 The pipe lance provides a solid and straight means of inserting and retracting the ConeBlast ½ Tool through the pipes to be blast cleaned. The pipe lance also provides an efficient means of conveying the abrasive/air mixture from the pressure blast pot to the ConeBlast tool. It is only advisable to utilize blasting hose for inserting and retracting the ConeBlast on smaller ID pipes ranging from 75mm (3 ) to 125mm (5 ) if necessary. Panblast always recommends the use of the correctly sized pipe lance. 3.3 The ConeBlast ½ assembly comes complete with a 32mm (1-1/4 ) connecting tube (YAC-BA-PB- 0007) in which the pipe lance can be screwed in to. It is recommended that the first 1 meter (3.3ft) of the pipe lance be a heavy wall pipe. Heavy wall pipe will compress the washer (YAC- BA-PB-0018) adequately and provides for increased wear protection of the tools internal components. For subsequent lengths of pipe to cater for the pipe being blast cleaned, the use of standard scheduled pipe is acceptable. To join the pipe lances together to meet the application requirements Panblast recommends the use of NTC-1 threaded couplings. Note: A pipe lance must be utilized on larger diameter pipes. The use of blasting hoses as the inserting and retracting mechanism will disrupt the abrasive/air mixture flow and will lead to premature damage of the tool components. 3.4 Fitting of the Collar & Button Set Carriage The ConeBlast ½ Internal Pipe Blaster BAC-BA-PB is supplied as standard with the full collar & button carriage system. The collar & button system comes complete with front & rear collars and four (4) sets of buttons (six (6) buttons per set). Refer to application table (2.2) for button selection for various pipe ID applications. To affix the collars to the tool, select the collar with the larger internal diameter and mount in position over the groove in the deflector pin holder (YAC-BA-PB-0006). The remaining collar, mount in position over the grove in the protection sleeve (YAC-BA-PB-0002). Both collars can then be secured in position by the socket head screws which will tighten in to the locating grooves. 3.5 Fitting of the Adjustable Scissor Carriage The adjustable scissor carriage is supplied as standard with fully threaded tip protection sleeve. To fit the ConeBlast ½ assembly in the adjustable scissor carriage: - Loosen the knurled lock nut (YAC-BA-PB-0003), remove the protection sleeve (YAC-BA-PB-0002), and replace with the fully threaded tip protection sleeve as supplied with the adjustable scissor carriage. - Screw the knurled lock nut (YAC-BA-PB-0003) back onto the fully threaded protection sleeve ensuring that the knurled lock nut is screwed all the way back to the deflector pin holder (YAC- BA-PB-0006). - Insert the ConeBlast ½ tool assembly from the rear of the adjustable scissor carriage, ensuring that the tool passes through the central collar and front yoke of the carriage. Position the groove in the deflector pin holder (YAC-BA-PB- 0006) with the central collar of on the scissor carriage and firmly secure with the set screw located within the central collar. - Screw the remaining knurled lock nut (supplied with the scissor carriage) onto the fully threaded tip protection sleeve. - To adjust the scissor centering carriage, turn the knurled lock nut in either a clockwise or anticlockwise direction for the required pipe ID application. 4.0 OPERATING INSTRUCTIONS 4.1 Read and fully understand all instruction as outlined in the pressure blast pot operator s manual and all accessories related to the operation. 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

5 4.2 Install the appropriate ConeBlast ½ Centering Carriage System and carefully adjust the carriage to ensure the tool is in the most central position of the pipe ID to be blast cleaned. 4.3 Connect the pipe lance or blast hose where appropriate to the tool assembly. 4.4 Place the full assembly inclusive of the carriage inside the entrance of the pipe; avoid any impact on the tungsten carbide deflection tip against the pipe wall. 4.5 Pressurize the blast pot and begin abrasive blasting. Ensure the abrasive to air mixture is set to maximum performance via the abrasive metering valve. A rich mixture of abrasives to air ratio will result in premature wear to the tool components. 4.6 Whilst the tool is at the pipe entrance, determine that you have the optimum abrasive flow setting and perform a small test blast to observe how fast the tool assembly should travel within the pipe for the desired cleaning result. 4.7 To commence production, push the complete tool assembly and carriage fully to the end of the pipe that is to be blast cleaned. Start the blast cleaning process and slowly retract the tool towards the pipe entrance point. Do not start the blasting process from the pipe entrance as this will create a build-up of abrasive media which can create the tool and carriage to jam within the pipe. 5.5 Inspect the stem support assembly taking particular note on the internal fins for wear, replace as soon as wear is observed. 5.6 Check and inspect the internal blast nozzle and tungsten carbide sleeves. Replace the blast nozzle when the orifice is worn 3mm (1/16 ) from its original size. 5.7 Ensure the flat washers (YAC-FN-PB-0177) located at each end of the carbide sleeves are in place and secure, replace if any signs of wear. 5.8 Periodically rotate the tungsten carbide deflection tip for even wear dispersion. Replace the deflection tip if any signs of wear are present. 5.9 Carefully check that all threaded parts are securely tightened to avoid gaps and voids which will create internal turbulence within the tool assembly. 6.0 TROUBLE SHOOTING GUIDE PROBLEM Abrasive blasting will not commence. PROBABLE SOLUTION Check the pressure blast pot for correct operation; refer to the pressure blast pot operator s manual. Isolate the compressed air source and inspect the ConeBlast tool for any obstruction within the internal bore. 4.8 Pipes that require an extensive blast cleaning process may need multiple passes. If after examination of the pipe it is determined a second blast is required it is recommended that any excessive spent abrasives be cleaned and removed from the pipe ID. Note: If it is necessary to remove the tool from the entrance of the pipe being blast cleaned it must be completely shut down. 5.0 MAINTENANCE INSTRUCTIONS! WARNING! THE SYSTEM MUST BE IN SHUT DOWN MODE AND THE COMPRESSED AIR DISCONNECTED BEFORE PERFORMING ANY INSTALLATION WORK. FAILIURE TO DO SO MAY RESULT IN PREMATURE ACTIVATION OF THE SYSTEM THAT MAY CAUSE SERIOUS INJURY OR DEATH. 5.1 Tungsten carbide internal parts within the ConeBlast are hard and brittle, do not drop or impact the tool assembly to avoid damage to these parts. 5.2 When undertaking periodic maintenance of the tool ensure that all abrasives, dust and debris are cleaned from all threaded sections prior to reassembly. Excessive wear on the Internal tool assembly. Check for moisture in the compressed air source. Install appropriate moisture control equipment if moisture is present. Check that all gaskets, washers and seals are correctly placed and securely fastened within the tool assembly. Ensure that the correct abrasive type and sizes are being utilized as per the abrasive recommendations within this operator s manual. Review the pipe lance and blast hose size and connection to the tool assembly as per section 3.0 of this manual. Rectify to the recommended size. Check the abrasive/air mix ratio from the pressure blast pot to the tool. Ensure the abrasive/air mixture is lean. If utilizing hard abrasive media ensure that the deflection tip has been upgraded to the PanBlast TM Boron Carbide Deflection Tip. 5.3 Inspect all gaskets, washers and seals, it is important to replace these items prior to excessive wear. 5.4 Inspect the internal lining in the deflection pin holder; replace the deflection pin holder when the lining show signs of wear. Centering carriage system does not suit the pipe ID. Refer to the application table (2.3) of this operator s manual. - 3

6 7.0 ASSEMBLIES, PARTS LISTING & EXPLODED VIEW 7.1 ConeBlast 1/2 Internal Pipe Cleaning Tool Assembly Item Stock Code Description Weight 18 BAC-BA-PB-0094 ConeBlast 1/2 Less Carriage 1.65 kg (3.63 lbs.) 19 BAC-BA-PB-0001 ConeBlast 1/2 Internal Pipe Blaster 3.13 kg (6.89 lbs.) 20 BAC-BA ConeBlast 1/2 Centering Carriage 1.85 kg (4.07 lbs.) 7.2 ConeBlast 1/2 Internal Pipe Blaster Parts Listing Item Stock Code Description Qty 1 YAC-BA-PB-0002 Protection Sleeve 1 2 YAC-BA-PB-0003 Lock Nut 1 3 BAC-BA-PB-0004 ConeBlast 1/2 Tungsten Nozzle 1 4 YAC-BA-PB-0005 Support Stem 1 5 YAC-BA-PB-0006 Deflector Pin Holder 1 6 YAC-BA-PB-0007 Connecting Tube 1 7 YAC-BA-PB-0008 Tip Holding Nut 1 8 YAC-BA-PB-0009 Deflection Tip - Tungsten 1 9 YAC-BA-PB-0010 Stem Extension Sleeve 1 10 YAC-BA-PB-0011 Throat Sleeve 1 11 YAC-FN-PB-0177 Flat Washer 3 12 YAC-BS-PB-0005 O-Ring 1 13 YAC-BA-PB-0017 Washer 1 14 YAC-BA-PB-0018 Washer 2 15 YAC-BA-PB-0012 Throat Rod With Tip 1 16 BAC-BA-PB-0066 ConeBlast 3-1/2" To 5" Button Set 1 17 BAC-BA-PB-0073 ConeBlast 1/2 Full Collar Set ConeBlast 1/2 Internal Pipe Blaster Exploded View - 4

7 7.4 ConeBlast 1/2 Centering Carriage Parts Listing Item Stock Code Description Qty 1 YAC-FN-PB-0288 E-Ring 8 2 YAC-BA Clamp Bracket 2 3 YAC-BA Nozzle Clamp 2 4 YAC-BA Nozzle Clamp Rod 2 5 YAC-BA Clamp Bracket 2 6 YAC-BA Tube - Short 1 7 YAC-BA Tube - Long 1 8 YAC-FN-PB-0235 Screw 8 9 YAC-FN-PB-0007 Flat Washer YAC-BA-PB-0036 Roller Wheel 8 11 YAC-BA-PB-0039 Wheel Bush 8 12 YAC-BA Outer Left Bracket 1 13 YAC-BA Inner Bracket 2 14 YAC-BA Bracket Supporting Rod 4 15 YAC-BA Outer Right Bracket 1 16 YAC-BA Shaft Rod - Long 1 17 YAC-BA Shaft Rod - Short 1 18 YAC-FN Screw 2 19 YAC-FN-PB-0017 Flat Washer 2 20 YAC-BA Connecting Tube Bracket 2 21 YAC-BA-PB-0038 Nylon Washer 2 22 YAC-BA-PB-0031 Tube Seat 1 23 YAC-BA-PB-0030 Threaded Tube 1 24 YAC-BA-PB-0003 Lock Nut 1 25 YAC-FN-PB-0237 Screw 1-5

8 7.5 ConeBlast 1/2 Centering Carriage Exploded View - 6

PRODUCT OPERATING MANUAL

PRODUCT OPERATING MANUAL PANBLAST TM AURORA LED HELMET & HOSE MOUNT KITS Manual Number: ZVP PC 0034 01 SECTION 1. GENERAL INFORMATION 2. INTRODUCTION 3. INSTALLATION 4. OPERATING INSTRUCTIONS 5. MAINTENANCE