PRODUCT OPERATING MANUAL PANBLAST TM CS37 SUCTION BLAST CABINET Manual Number: ZVP PC 0069 00
SECTION 1. GENERAL INFORMATION 2. ASSEMBLY & INSTALLATION INSTRUCTIONS 3. OPERATING INSTRUCTIONS 4. MAINTENANCE 5. TROUBLE SHOOTING GUIDE 6. ASSEMBLIES, PARTS LISTING & EXPLODED VIEW BLAST CABINET SERIAL NUMBER:
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 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. 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 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 anyone else in the immediate area that may be exposed to any hazards generated by the 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 tradesmen. 1.3.4 Under no circumstances should any safety interlocks 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 Data Sheet on the abrasive 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 before start up 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 couplings have engaged correctly, the safety pins are fitted and in good order, always install safety cables at every connection. Ensure that the nozzle has been securely screwed into the holder and the holder has been secured to the hose correctly and all screws are engaged. 2.0 ASSEMBLY & INSTALLATION INSTRUCTIONS 2.1 The blast cabinet is a freestanding unit, which should be installed in a dry area, on a flat and level surface. It is recommended a clear area of 1200mm (47 ) be provided around all sides of the cabinet to provide access for operation, loading and servicing. 2.2 It is recommended that the cabinet should be permanently fixed in position with suitably sized fasteners for added stability and safety during use. 2.3 Remove all cabinet components from the shipping crate, and then remove all parts from inside the cabinet sub assembly. 2.4 Invert the cabinet sub assembly onto its top, so that the cabinet hopper is pointing directly upwards. 2.5 Attach the four (4) cabinet legs to the cabinet, using the 1/4 x 1/2 bolts provided. Note that each of the rear legs also requires 2 x selftapping screws provided. 2.6 With the legs securely attached, invert the cabinet upright onto the four (4) legs. 2.7 Position the foot pedal switch on the floor between the front legs. 2.8 Attach the two (2) side doors to the cabinet, ensuring the hinges are located on the outside of the cabinet door opening. 2.9 Attach the two (2) door latches to the front of the cabinet, moving them out to their full extent. Close the side doors, and adjust the latches inwards to tighten the door seals if required. 2.10 Place the cabinet light glass on top of the cabinet light opening, and then position the light assembly over the light glass with the light switch on the right side. Secure the assembly in position using four (4) of the 1/4-1 -
x 3/4 bolts and nuts provided. 2.11 Attach the dust collector body to the rear panel (right side) aligning the intake tube with the rear panel hole. Fix in position using four (4) of the 1/4 x 3/4" bolts provided. 2.12 Place the dust collector motor and filter assembly into the top of the dust collector body and lock in position using the 2 latches provided. 2.13 Remove the inlet box that covers the dust collector intake tube hole from the rear panel of the cabinet. Apply a bead caulking around the tube to seal it, then fit sponge filter media into box (to protect fan motor from dust) and refit the inlet box. 2.14 Place the cabinet floor grate into the cabinet ensuring the corner cut out is located in the right hand front corner of the cabinet to allow the suction gun hoses to pass through. 2.15 Check that all securing nuts, bolts and screws are correctly tightened. 2.16 Connect the dust collector plug into the female socket coming from the light assembly, and then connect the plug from the light assembly into the power supply socket. 2.17 Take the self-locking air connection fitting from the inner packing. Wrap a thread sealing tape round the fitting thread. Screw it into the air inlet hole on the rear side of the electrical control box and tighten. 2.18 Push the coupler to the self-locking fitting toward the air inlet hole, the cone shaped end of the connector will immediately pop out. Fit it into the air hose connecting to the air compressor, fasten with a hose clamp. Push the coupler again and fit in the opposite side of the cone shaped end, release and the connection is secure. 2.19 Remove the suction head from the fixed gun assembly, fit in the air jet, re-connect the suction head and tighten. Loosen the M6 screw on the side of the gun and install the corresponding blast nozzle (orifice size should be twice the size of the air jet), tighten the screw. 2.20 Connect the side branch of the gun assembly with a suction hose. Connect the rear inlet of the gun to the flexible metal hose in the cabinet, screw until secure. 2.21 Connect the other end of the suction hose to the corresponding suction pipe. 2.22 Connect one end of the high pressure air hose to the air connector on the right side of the electrical control box, the other end to the air inlet on the movable gun, secure with hose clamps. 2.23 Connect one end of the suction hose to the side branch of the movable gun assembly, the other to the fixed suction pipe. 2.24 Installation of the air jet and nozzle are the same as the fixed gun assembly. 3.0 OPERATING INSTRUCTIONS 3.1 Cabinet Operation 3.1.1 Assemble and install the blast cabinet as detailed in Section 2.0 of this manual. 3.1.2 The air jet should be approximately half the size of the nozzle. 3.1.3 Pour abrasive media approximately 18 kg (40lb) into the cabinet hopper through the side door of the cabinet. 3.1.4 Turn on the compressed air supply, when the air pressure reaches 415 Kpa (60 PSI), press the power switch to ON, the power indicator should then light up.! WARNING! NEVER EXCEED MAXIMUM OPERATING PRESSURE OF 125PSI (8.6BAR), AS THIS MAY RESULT IN SERIOUS INJURY OR DEATH. 3.1.5 The machine comes with two (2) blasting guns, but under the control of an electric/pneumatic system where only one gun is operable at any one time. When the movable gun and door closed indicators on the control panel are illuminated then the movable gun is available for operation. Step on the pedal switch and the movable gun shuts down and the fixed gun operates immediately, this will be seen on the control panel indicators. 3.1.6 There are limit switches located inside each door to sense when the doors are open or closed. If the door closed indicator on the control panel is not illuminated, the system is then in a protection mode and the fixed gun will not operate. 3.1.7 When the air pressure exceeds 60 PSI, the user can operate the machine. First insert arms into the rubber gloves, grasp the work piece to be blasted, position it under the fixed gun, step on the pedal switch and then the blasting process begins. Alternately grasp the movable gun, point the nozzle at the work piece, press the trigger and the blasting process begins, check the work piece to ensure the desired result has been obtained. 3.1.8 The abrasive media will drop into the bottom of the cabinet hopper to be recycled during the blasting process. Note: To ensure reliable blasting the compressed air should be dry, if it contains too much moisture, a moisture separator should be installed immediately before the air enters the connection to the control box. 3.2 Illumination and Electro-Pneumatic System - 2 -
3.2.1 The pneumatic system is controlled by an electric circuit, which is set inside the control box located on top of the cabinet. A layout of the front panel of the box is shown below in Figure 1. 3.3 Control Panel Functions and Indicators 3.3.1 Item 1 Fuse - A safety feature for overload and short circuit protection. 3.3.2 Item 2 Power switch - To connect or disconnect the power supply. 3.3.3 Item 3 Light switch - To turn the cabinet light on or off. 3.3.4 Item 4 Power indicator Illuminates when the power supply is connected. 3.3.5 Item 5 Door closed indicator - Illuminates when the doors are closed and fixed gun is operable. 3.3.6 Item 6 Fixed gun indicator - Illuminates when the fixed gun is in operation. 3.3.7 Item 7 Movable gun indicator - Illuminates when the movable gun is operable or in operation. 3.3.8 Item 8 Air pressure gauge - Indicates blasting air pressure. 3.3.9 Item 9 Air pressure valve - Regulates the blasting air pressure, turn clock wise and pressure increases, turn counter clock wise and pressure decreases. 3.3.10 Item 10 Pedal switch - Controls operation of the fixed gun. 3.3.11 Item 11 Electro-magnetic valve - Controls the selection of the blasting mode required. 3.4 Electric Control Box Note: If the control system breaks down or malfunctions have it repaired by a qualified technician. 3.5 Control of the Blasting Action 3.5.1 Choose a nozzle and air jet of suitable size according to the desired grade of fineness or coarseness of surface finish required. Also check the air volume required for the nozzle at the required blasting pressure against the compressed air supply available. 3.5.2 Use a suitable grade of abrasive to achieve the desired surface finish. 3.5.3 The operator should now manipulate the blast gun or work piece to move the blasting action over the surface of the component being blasted, until the desired result is achieved. Smooth, continuous strokes over the component surface are normally the most effective, with the nozzle being held approximately 75mm (3 ) to 125mm (5 ) from the component surface. 3.5.4 The air pressure should remain stable during blasting. 3.5.5 Ensure there is good lighting of the cabinet work area. 3.5.6 To stop the blasting action, the operator, in the case of the movable gun releases the gun trigger, and in the case of the fixed gun changes the mode by depressing the foot pedal. 3.5.7 Allow a few moments for the fan and dust collector to clear the airborne dust from the cabinet before opening the cabinet door and removing the blasted component(s). 3.5.8 Close the door, shut off the compressed air supply, and switch off the cabinet light and dust collector fan assembly and power supply. 3.4.1 Connect the power cord on the rear panel to a grounded power supply. 3.4.2 Press the power switch to ON, the power indicator will immediately light up, if not, check the power supply and cord, also check the fuse has not blown. Replace with fuse of the same rating. 3.4.3 Press the light switch ON, the light will illuminate immediately. 3.4.4 The door status tester is a feature designed to protect the operator and surrounding environment from the abrasive blasting process if a door should be inadvertently opened. When the door-closed indicator is illuminated, it indicates the doors are securely closed and the fixed gun is operable under the control of the pedal switch. Note: Never operate the blast system with any of the cabinet doors open, as serious injury may occur. - 3 -
Figure 1 1. Fuse 2. Power Switch 3. Light Switch 4. Dust Switch 5. Power Switch 6. Control Indicator 7. Door-Closed Indicator 8. Fixed Gun Indicator 9. Movable Gun Indicator 10. Air Pressure Gauge 11. Air Pressure Valve - 4 -
4.0 MAINTENANCE Note: Always ensure both the compressed air supply and electrical power supply has been isolated from the cabinet prior to carrying out any maintenance. Over a period of time, dust and debris will build up in the abrasive mix, which will cause a loss of blasting performance, poor visibility in the cabinet and poor surface finish. The abrasive should be drained from the cabinet and new clean abrasive loaded into the cabinet. 4.1 Suction Gun Assembly 4.1.1 On a monthly basis, remove the blast nozzles from both the fixed and movable guns, and inspect both nozzles and air jets for wear. If an air tip is worn sufficiently to have either worn through completely, or caused damage to the air tip discharge opening, it should be replaced. 4.5 Cabinet Window 4.5.1 Over a period of time, the cabinet viewing window cover will become frosted by the impact from rebounding abrasive. The window cover can be replaced. Peel the cover from the window, and then clean the dust from the inside surface of the window using a non-oil based cleaning solvent. Remove the protective backing tape from the new window cover, and attach it to the inside surface of the window. 4.6 Rubber Seals 4.6.1 On a weekly basis, inspect the main cabinet door seal around the door opening for wear and damage. Also inspect the abrasive hopper seal and the dust collector inspection door seal for wear and damage. Replace all seals as required. 4.1.2 If a blast nozzle is worn by 1mm (0.040 ) or more from its original size or the internal surface is grooved or damaged, then the blast nozzle should be replaced. 4.2 Blast Hose 4.2.1 On a monthly basis, inspect the abrasive supply hose along its length by feeling for soft spots, which will indicate areas of wear, replace as required. 4.3 Dust Collector 4.3.1 On a weekly basis, or when the visibility within the cabinet becomes poor, with the dust collector fan turned off, operate the dust filter rapping device for approximately 10-15 seconds to shake the dust build up from the dust filter. Wait a few moments for the dust to settle, then open the drain valve on the bottom of the dust collector and drain the dust into a refuse dustbin. When all the dust has completely drained out, close the drain valve. 4.3.2 After every five (5) hours of operation, or If the visibility in the cabinet continues to be inadequate after the dust collector filter has been rapped, it may be necessary to remove the filter cartridge from the dust collector, and blow it down from the inside out, with compressed air. Be careful not to damage the filter cartridge media while blowing down, and do not attempt to wash the filter cartridge with water or any other fluid. 4.3.3 If blowing the filter cartridge down with compressed air does not clean it adequately, or dust is discharged from the dust collector outlet, the filter cartridge should be replaced. 4.4 Cabinet Gloves 4.4.1 On a weekly basis, give the cabinet gloves a visual inspection and check for holes and signs of deterioration. Replace the gloves as necessary. - 5 -
5.0 TROUBLE SHOOTING GUIDE Item Problem Possible Cause Remedy 1 Abrasive flow decreasing Abrasive build-up in the nozzle Wet abrasive, have it dried Drain water from the air compressor 2 The blasted surface not as coarse or as fine as desired Wrong grade of abrasive media Replace with abrasive media of right grade 3 Uneven blasting Abrasive media worn Strain or replace the abrasive media 4 Light failure The transformer is damaged Replace the transformer The light is damaged Replace the light Bad contact Have it repaired by a qualified technician 5 Dust leakage The viewing window is not sealed properly The door is not sealed properly Replace the corresponding foam sealing strip The funnel is not sealed properly - 6 -
6.0 ASSEMBLIES, PARTS LISTING & EXPLODED VIEW 6.1 CS37 Suction Blast Cabinet Assemblies Stock Code Description Shipping Weight BEC-CA-0512-00 CS37 Blast Cabinet - 240VAC 105Kg (231.48 lbs) BEC-CA-0518-00 CS37 Blast Cabinet - 110VAC 105Kg (231.48 lbs) 6.1.1 CS37 Suction Blast Cabinet Parts Listing Item Stock Code Description Qty 1 BAC-CA-0482-00 Window Cover 1 2 BAC-CA-0527-00 Light Window Cover Pack of 5 1 3 BAC-DF-0022-00 Dust Collector Filter 1 4 BAC-GL-0006-00 Cabinet Gloves 1 PAIR 5 BAC-CA-0480-00 Glove Clamps 1 6 BAC-CA-0538-00 Electric Foot Pedal 1 7 BAC-BG-0098-00 Suction Gun Assembly w/o Nozzle & Suction Gun Barrel 1 8 BAC-NZ-0508-00 6mm Ceramic Nozzle 1 9 BAC-BG-0127-00 Suction Gun Barrel (not shown in illustration) 1-7 -
6.1.2 CS37 Suction Blast Cabinet Product Exploded View - 8 -