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 6. TROUBLE SHOOTING GUIDE 7. ASSEMBLIES, PARTS LISTING & EXPLODED VIEW
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 or distributor 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 air supplied 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(s) 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 person. 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 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 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(s) and all personnel. 1.3.10 The operator should carry out a daily inspection before start-up of all wearing and safety items to ensure that they are in correct operating order. In particular check all blast hose couplings and nozzle holders, ensuring that all couplings have engaged correctly and the safety locking pins are fitted and in good order. Always install safety whip check cables at every 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 that all screws are engaged. 2.0 INTRODUCTION 2.1 Scope. These instructions cover the installation, operation and maintenance of the PanBlast Aurora LED Blasting Light Assemblies 2.2 Application. The PanBlast Aurora LED Blasting Lights are designed to provide advanced and targeted lighting for abrasive blasting applications. 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. 3.0 INSTALLATION! WARNING! THE SYSTEM MUST BE IN SHUT DOWN MODE AND THE COMPRESSED AIR AND ELECTRIC SOURCE DISCONNECTED TO THE ABRASIVE BLASTING EQUIPMENT BEFORE PERFORMING ANY INSTALLATION WORK. FAILIURE TO DO SO MAY RESULT IN PREMATURE ACTIVATION OF THE SYSTEM THAT MAY CAUSE SERIOUS INJURY OR DEATH. 3.1 The PanBlast Aurora Blast Light is an LED style lamp, which is powered by either a 3.7Volt rechargeable lithium Ion battery, or a 12V battery/power supply, depending on which model is being utilized. 3.2 The Aurora LED style lamp is generally maintenance free, generates no heat and provides much higher levels of illumination compared to other conventional style lamps. - 1 -
3.3 The LED lamp itself is protected from the abrasive blasting action by a replaceable glass lens (BAC-BA-PB-0059). 3.4 Preparation for operation of the 12V hose mounted Aurora LED Light Assembly: codes BAC-BA-0130 & BAC-BA-PB-0129. 3.5 Check that the protective glass lens (BAC-BA-PB- 0059) is held firmly in place by the lens retaining ring (YAC-BA-PB-0086) by ensuring it is screwed hand tight onto the front of the Aurora LED Light Assembly.. 3.6 Ensure that all connecting cables and cable connectors are in good condition, and that there are no exposed wires or damaged / worn terminals. 3.7 Using cable ties, heavy cloth tape or similar, attach the Aurora Hose Mounting Assembly (YAC-BA-PB-0128) in the up right position, to the blast hose, in a location directly adjacent to the blast nozzle holder. Ensure that the light mounting face of the bracket is facing towards the blast nozzle end of the blast hose assembly. It is recommended that the remote control handle be positioned directly behind the Aurora LED Light Assembly. for optimum results. 3.8 Attach the light assembly (BAC-BA-PB-0113) to the hose mounting assembly by sliding the light onto the mounting face on the front of the bracket. 3.9 Uncoil the extension cable assembly (either BAC-BA-PB-0105 or BAC-BA-PB-0097) and lay it out along the length of the blast hose. 3.10 Connect the blast light cable connector to the connector on the end of the extension cable by pushing the two connectors together, and then rotate the retaining nut to lock the cable connectors in position. 3.11 Using cable ties or heavy cloth tape, attach the extension cable to the blast hose at approximately 500mm (20 ) intervals, commence the attachment directly behind the extension cable connector. 3.12 Using the same method as 3.10 now connect the alligator clip extension (BAC-BA-PB-0112) to the opposite end of the extension cable. 3.13 Carefully now connect the red alligator clip to the positive (+) and then connect the black alligator clip to the negative (-) side of a12volt power supply.! WARNING! NEVER CROSS CONNECT THE POSITIVE AND NEGATIVE CONNECTIONS, AS DAMAGE TO THE AURORA LED LIGHT ASSEMBLY AND/OR POWER SUPPLY MAY OCCUR. IT IS RECOMMENDED THAT THE POWER SUPPLY NOT BE CONNECTED TO THE AURORA LED LIGHT ASSEMBLY UNTIL IT IS READY FOR IMMEDIATE OPERATION. 3.14 The blast light is now ready for operation. 3.15 Preparation for operation of the 3.7 Volt rechargeable Aurora LED Helmet Mounted Assembly: code BAC-BA-0075-06. 3.16 Connect the alternate battery charger unit either (BAC-BA-PB-0115) or (BAC-BA-0173-00 for Australia) to a suitable 100 to 250Volt power supply, and attach the (BAC-BA-PB-0109) Aurora 3.7v LED lamp battery pack kit to the battery charger by pushing the cable connectors together, and locking them in position by rotating the connector locking nut. 3.17 The recommended minimum charge time for initial operation is twelve (12) hours. 3.18 Once fully charged, disconnect the battery pack kit from the battery charger. 3.19 Ensure that the blast helmet outer surface is free from all dust, dirt, oil etc.. If necessary, carefully clean and dry the blast helmet outer shell using a mild detergent. 3.20 Carefully remove the backing tape from one side of the Aurora LED Blast Helmet Fastener Kit (BAC-BA-0215-00), and carefully attach it to the top center section of the outer blast helmet shell in a direction from the front viewing lens towards the rear air inlet fitting. 3.21 Remove the side of the backing tape of the fastener kit. Mount the helmet light mounting kit to the helmet by firmly pressing the base (item 4) onto the fastener on the blast helmet, ensuring that the light holder is facing towards the front of the blast helmet. 3.22 Carefully attach the Aurora LED Light Assembly to the mounting bracket by sliding the Aurora LED Light Assembly. onto the mounting face. 3.23 Attach the battery pouch BAC-BA-PB-0090 to the operator s blast helmet alternate controller waist belt, and attach the belt around the operator s waist in the normal manner. 3.24 Insert the battery pack into the battery pouch, and connect the battery pack to the Aurora LED Light Assembly by pushing the cable connectors together, and locking them in position by rotating the connector-locking nut. 3.25 The Aurora LED Blast Light is now ready for operation. 4.0 OPERATING INSTRUCTIONS 4.1 Ensure that the Aurora LED Blast Light Assembly has been setup and checked as detailed in section 3.0 of this manual. 4.2 Operation of all Aurora LED Blast Light models is by simply rotating the control knob located on the right hand side of the light assembly in the clockwise direction. This will illuminate the LED within the light assembly. To turn the light off, simply rotate the control knob in an anticlockwise direction. 4.3 While using the Aurora LED Light, care should be taken to prevent damage to the light as much as possible in order to maximize its operating life. 4.4 Under normal operating conditions, a single battery charge should provide a lighting operational time of approximately twenty (20) hours. - 2 -
4.5 The Aurora LED Light should always be positioned and/or adjusted in a manner to direct the LED light b e a m directly onto the area being abrasive blasted. Note: The Aurora Blast Lights are not a substitute for ambient lighting. Panblast recommends that separate adequate ambient lighting should be used in all abrasive blasting applications within confined or dark spaces/areas to ensure a safe working environment. 5.0 MAINTENANCE 6.0 TECHNICAL DATA Stock Code BAC-BA-0075-06 BAC-BA-PB-0082 Rated Voltage 3.7Volt 12Volt Nominal Capacity 6Ah Lighting Time >20H 3.7Volt 12Volt LED Light Source 0.7/0.7A(Double Filament)! WARNING! THE SYSTEM MUST BE IN SHUT DOWN MODE AND THE COMPRESSED AIR AND ELECTRICAL SOURCE DISCONNECTED BEFORE PERFORMING ANY MAINTENANCE WORK. FAILURE TO DO SO MAY RESULT IN PREMATURE ACTIVATION OF THE SYSTEM THAT MAY CAUSE SERIOUS INJURY OR DEATH. 5.1 The solid state, LED design of the Aurora Blast Lights ensures that they are basically maintenance free and under normal circumstances, require only the replaceable glass protection lens to be replaced as required. 5.2 During normal abrasive blasting operations, the blast light lens (BAC-BA-PB-0059) will become frosted by the rebounding abrasive media generated by the abrasive blasting action. Over a period of time this may cause the level of illumination to be reduced. 5.3 To replace the protection lens, simply unscrew the blast light glass holder (YAC-BA-PB-0086) and remove the old lens. Insert a new protection lens in place, and screw the blast light glass holder back into position. Replacement lenses are available in packets of 5 lenses, stock code BAC -BA-PB-0093. 5.4 On a regular basis, check the condition of all cables and cable connectors. Check for any signs of deterioration or wear or exposed wiring. Replace as necessary. 5.5 The Aurora LED Blast Light Assembly and all components including the battery charger must be kept dry and away from moisture at all times. 5.6 Clean as required using only a clean dry cloth or brush. Maximum Illumination Li-ion Storage Battery Life Light Start->=1300Lx After11H->=1000Lx >=500cycles N/A - 3 -
7.0 ASSEMBLIES, PARTS LISTINGS AND EXPLODED VIEW 7.1 Aurora Helmet Blast Light Assembly Stock Code Description Weight BAC-BA-0075-06 Aurora Helmet Blast Light Mounting Kit 1.45 Kg (3.19 lbs) ABOVE ITEM REQUIRES ONE OF THE FOLLOWING CHARGERS TO BE ORDERED AT THE SAME TIME: BAC-BA-0173-00 Aurora LED Blast Light Charger (Australian Market Only) BAC-BA-PB-0115 Aurora LED Battery Charger Kit (All Other Markets) 0.28 Kg (0.62 lbs) 7.1.1 Aurora Helmet Blast Light Parts Listing Item Stock Code Description Qty 1 YAC-BA-PB-0083 Light Holder 1 2 YAC-BA-PB-0076 Adjustable Helmet Mounting 1 3 YAC-BA-PB-0077 Holder Base 1 4 YAC-BA-PB-0078 Base 1 5 YAC-BA-PB-0092 Base Top Plate 1 6 YAC-FN-PB-0261 Screw 2 7 YAC-FN-PB-0262 Wing Nut 1 8 YAC-FN-PB-0255 Hex Head Bolt 1 9 YAC-FN-PB-0120 M4 Nut 2 10 YAC-FN-PB-0121 Spring Washer 1 11 BAC-BA-0215-00 Aurora LED Blast Helmet Fastener Kit 1 12 BAC-BA-PB-0059 Aurora LED Glass 1 13 YAC-BA-PB-0086 Glass Holder 1 14 YAC-BA-PB-0087 Switch Knob 1 15 BAC-BA-PB-0114 Aurora LED 3.7V Lamp Kit 1 16 BAC-BA-PB-0090 Aurora LED Blast Light Battery Pouch 1 17 BAC-BA-PB-0109 Aurora LED Battery Pack 1 7.1.2 Aurora Helmet Blast Light Service Kit Stock Code BAC-BA-PB-0093 Description Aurora LED Lens Kit Includes Item12 (5 off) - 4 -
7.1.3 Aurora Helmet Blast Light Exploded View - 5 -
7.2 Aurora LED Hose Mount Kit Assembly Stock Code Description Weight BAC-BA-PB-0082 Aurora LED Hose Mount Kit 1.0Kg (2.2lbs) BAC-BA-PB-0129 Aurora LED Hose Mount With 55ft Cable (Includes Item14) 3.1Kg (6.8lbs) BAC-BA-PB-0130 Aurora LED Hose Mount With 20m Cable (Includes Item15) 3.7Kg (8.2lbs) 7.2.1 Aurora LED Hose Mount Parts Listing Item Stock Code Description Qty 1 YAC-BA-PB-0083 Light Holder 1 2 YAC-BA-PB-0084 Hose Holder Base 1 3 YAC-BA-PB-0085 Hose Base 1 4 YAC-FN-PB-0255 Hex Head Bolt 1 5 YAC-FN-PB-0120 M4 Nut 2 6 YAC-FN-PB-0121 Spring Washer 5 7 YAC-FN-PB-0234 Screw 4 8 YAC-FN-PB-0074 Hose Clamp 2 9 BAC-BA-PB-0112 Aurora LED Alligator Clips 1 10 BAC-BA-PB-0113 Aurora LED 12v Lamp Kit 1 11 BAC-BA-PB-0059 Aurora LED Glass 1 12 YAC-BA-PB-0086 Glass Holder 1 13 YAC-BA-PB-0087 Switch Knob 1 14 BAC-BA-PB-0105 Aurora LED 55ft Cable Ext Kit 1 15 BAC-BA-PB-0097 Aurora LED 20m Cable Ext Kit 1 7.2.2 Aurora LED Hose Mount Service Kit Stock Code Description BAC-BA-PB-0093 Aurora LED Lens Kit Item11 (5 off) BAC-BA-PB-0096 Aurora LED 12V Blast Light Set Includes Items 9, 10, 11, 12 & 13-6 -
7.2.3 Aurora LED Hose Mount Kit Exploded View - 7 -