xxxxxxxx Economy - Series Suction Blast Cabinets Superior Performance And Quality In Blast Cleaning Equipment E-Series Owners Manual Ph: (780) 466-5085 www.modublast.com Fax: (780) 465-7317
MOD-U-BLAST WARRANTY MOD-U-BLAST EQUIPMENT IS COVERED BY A ONE (1) YEAR WARRANTY AGAINST DEFECTS IN MATERIAL AND WORKMANSHIP STARTING FROM THE DATE OF PURCHASE. THIS COVERS THE EQUIPMENT, ALL MAJOR COMPONENTS AS WELL AS THE ELECTRICAL SYSTEM. THIS WARRANTY DOES NOT APPLY TO ABNORMAL USE OF THE MACHINE OR PARTS. PARTS SUBJECT TO ABRASIVE WEAR SUCH AS NOZZLES, GLOVES, HOSES, DRY FILTERS, WINDOWS AND WINDOW PROTECTORS ETC. ARE NOT COVERED BY WARRANTY. CLAIMS WILL BE HONOURED ONLY IF THE WARRANTY CARD IS RETURNED WITHIN A PERIOD OF TWO (2) MONTHS FROM THE FACTORY SHIPPING DATE. THE CARD CAN BE RETURNED TO YOUR MOD-U-BLAST SALESPERSON OR MAILED TO THE ADDRESS BELOW. FOR SERVICE OR SUPPORT PLEASE CONTACT THE MOD-U-BLAST SERVICE CENTRE AT 1-800-661-3842 EDMONTON OFFICE. P.O. BOX 79037, RPO NOTTINGHAM SHERWOOD PARK, ALBERTA CANADA T8A 5S3 PH. (780) 466-5085 FAX (780) 465-7317 www.modublast.com 1
CONTENTS 1. IMPORTANT NOTICE 3 2. IMPORTANT WARNING 4 3. ASSEMBLY INSTRUCTIONS FOR E SERIES CABINETS 5 4. DESCRIPTION 6 5. GENERAL OPERATING INSTRUCTIONS 6,7 6. E SERIES MAINTENANCE 7,8 7. SUPPLY AIR PIPE SIZE & AIR REQUIREMENTS 9 8.MAINTAIN SUCTION EFFICIENCY WITH SIMPLE STEPS 10 9. GLASS BEAD INFORMATION 11 10. E SERIES CABINETS PARTS LIST 12,13 11. SUCTION GUN ASSEMBLY 14,15 12. E SERIES DUST COLLECTORS 16 13. E SERIES PNEUMATIC DRAWING 17 14. E SERIES ELECTRICAL DRAWING 18 15. CSA CERTIFICATE OF COMPLIANCE 19 2
1. IMPORTANT NOTICE TO DISTRIBUTORS, PURCHASERS AND END USERS OF MOD-U-BLAST PRODUCTS The information provided described and illustrated in this material is intended for experienced, knowledgeable users of abrasive blasting equipment and supplies (products). The products described in this material may be combined as determined solely by the user in a variety of ways and purposes. However no representations are made as to intended use, performance standards, engineering suitability, safe practices or compliance with government regulations and laws that apply to these products, products of others, or a combination of various products chosen by the user or others. It is the responsibility of the users of these products, products of third parties, and a combination of various products, to exercise caution and familiarize themselves with all applicable laws, government regulations and safety requirements. Nor are representations made or intended as to the useful life, maintenance cycles, efficiency or performance of the referenced products of any combination of products. This material must not be used for estimating purposes. Production rates, labour performance or surface finishes are the sole responsibility of the user based on the user's expertise, experience and knowledge of industry variables. It is the responsibility of the user to insure that proper and comprehensive training of operators has been preformed and all environmental and safety precautions observed. Mod-U-Blast. provides a variety of excellent products to the surface preparation industry, and we are confident that all proficient users, operators and contractors in this industry will continue to use our products in a safe and knowledgeable manner. Before using this product, read all instructions, literature, labels, specifications and warnings sent with and affixed to the unit. If operation of the unit is unclear after reading this manual, contact your supervisor for instructions. It is the responsibility of the employer to read the following instructions to users of this equipment, who are unable to read. Periodic inspection at the work site should be made by supervisory personnel to ensure the blast machine is being properly used and maintained. A copy of this owner's manual must be kept with the blast machine and readily accessible to the blast machine operators at all times. 3
2. IMPORTANT WARNING Read all instructions before using this equipment. For efficient and safe production, reference OSHA requirements. Remember: 2.1 Start up preparations: - Supply air line should be sized according to the table shown on page 9. All hoses should be rated at least 125 psi and an isolation valve should be installed so that supply air can be turned off and then disconnected from blast machine for servicing. - Supply air should be dry and clean from oil and other contaminants. (ie use air dryer, coalescent filter, or moisture separator as needed.) - Blast machine must be grounded to avoid shock. - Electric extension cords should be three wire grounded, and rated for the amperage of the blaster. Check nameplate for rated amps. 2.2 Operator's responsibilities before staring: - Inspect fittings and hoses for damage and wear. - Check the seal on all doors. Only operate the blast cabinet with all doors securely closed and dust collection system running. - Clean dust from dust collector and clean filter as needed. 2.3 Caution: - Watch for silicosis (from dust created when using silica sand as a blast media) or toxic dust hazard. DO NOT USE MEDIA CONTAINING FREE SILICA. - Unless otherwise specified, working pressure of blast machine and related components must not exceed 125 p.s.i. - Keep blast nozzle controlled and aimed at the work. 2.4 Maintenance - Keep your machine in good repair. Use MOD-U-Blast parts and do not substitute or modify MOD-U- BLAST supplied items. 4
3. E SERIES ASSEMBLY INSTRUCTIONS 3.1 Remove all parts from inside crate including floor grate from bottom of crate, underneath cardboard. 3.2 Remove all parts from inside cabinet. 3.3 Place cabinet on its top with light hole facing down 3.4 Attach legs using four 1/4 x ½" bolts. a)front left leg has name plate. b)rear legs will also take 2 self tapping screws each. 3.5 Stand cabinet upright on legs. 3.6 Attach bracket with pressure gauge (#8 on pg.12) to left front leg with two 1/4 x 3/4" bolts, lock washers and nuts. 3.7 Place foot pedal between front legs. 3.8 Attach metering valve (#13) using three self tapping screws to back bottom on cabinet. Snap closed with door catch. 3.9 Attach left and right doors (#6) with four #8-32 nuts. 3.10 Loosen bolts on door catches (#20) and move out to full extent and tighten bolts. Moving them in slightly will tighten door seal. 3.11 Place glass on top of cabinet.(#4 on pg. 12) 3.12 Place light fixture (#1) on glass with light switch on right side. Fasten to cabinet with four 1/4 x 3/4" bolts and flat washers. 3.13 Dust Collector a) Attach body of dust collector to rear panel (right side) aligning pipe with hole. Use 1/4 x 3/4" bolts and flat washers. b)place top of dust collector (with motor and filter) into top of unit. Do up the 2 catches. c) Remove inlet box that covers the dust collector pipe inside the cabinet and place a bead of caulking around pipe to seal it. Replace inlet box. OR Vacuum a) Attach flex hose from side inlet of vacuum to hole at the back of the cabinet. 3.14 Tighten all bolts, nuts and screws. 3.15 Place floor grate with cut out corner to front right of cabinet. Bring hoses through opening. 3.16 Plug dust collector or shop vacuum into female plug coming from light. Then plug male cord from light into 115 Volt 60 Hz supply. On/Off switch controls the vacuum, lights and / or dust collector. 3.17 Put media into cabinet through floor grate.(approximately 1/4 bag.) 5
4. GENERAL DESCRIPTION This Owners Manual covers E SERIES cabinets manufactured by MOD-U-BLAST. MOD-U-Blast manufactures two sizes of E series cabinets: 36" and 48". Each can be purchased with either a dust collector, a shop vacuum or without any dust collection. The customer is expected to supply a dust collection system if a cabinet is purchased without one. It should be rated approximately 100 c.f.m. (cubic feet per minute). The E Series cabinets are ideal for smaller operations where use will be less than continual, or for clean uses. They require little space but have many features usually found only on larger industrial cabinets. 5. OPERATING INSTRUCTIONS 5.1 Preparing parts for blasting - All parts processed must be relatively free of oil, grease and moisture. Make sure parts are dry before putting into the cabinet for cleaning. 5.2 Air pressure - Operating Pressure: from 50 to 100 psi. (pounds per square inch) - Higher pressures (up to 125) can be used but this breaks down some types of medias prematurely.(ex. glass bead) - Set air pressure to 80 psi. Most parts for blast cleaning can be blasted at 80 psi. For light gauge steel, Aluminum, and other more delicate parts, start at lower pressure and gradually increase the pressure until the desired finish is achieved. WARNING: DO NOT CONNECT TO HIGH PRESSURE BOTTLE GAS...RUPTURE AND EXPLOSION CAN OCCUR. 5.3 Gun angle and distance - Direct gun at parts at 45-60 degree angle with ricochet towards the back of the cabinet. Do not hold gun at 90 degree angle to parts being processed. This will cause the media blast to bounce back into the blast stream and slow blasting action. Also 90 degree angle will cause excessive wear on gun and viewing window. Hold gun approximately 6 inches from parts being blasted. WARNING: GUN MUST ALWAYS BE POINTED AWAY FROM THE OPERATOR AND TOWARDS ITEMS BEING PROCESSED. NEVER BLAST WITH ANY OF THE CABINET DOORS OPEN. WHILE LOADING AND UNLOADING, NO ONE SHOULD BE AT THE OPERATOR STATION, AT THE FRONT OF THE BLAST CABINET. - Optional safety doors are available so that the gun cannot be operated unless the doors are closed. Contact your MOD-U-BLAST dealer for further information. 6
5.4 Media - Media should be of good quality and dry. Moisture will cause the media not to flow and will clog metering valve and hopper. NEVER USE SAND IN YOUR BLAST CABINET There are many types and sizes of media for different finishes. If you are having a problem selecting a media for a specific job, contact your distributor for recommendations. 5.5 Metering Valve - The metering valve adjusts the amount of media being pulled into the venturi gun. This valve, located at the bottom of the hopper, has the media stored on top of it. When air is sent to the gun from the foot pedal a vacuum is created that sucks air and media up into the gun through the clear media hose. A 7/16" bolt on the top of the metering valve can be adjusted to vary the amount of air that is sucked in through the holes. If the holes are too far closed, the mixture will have too much media and the gun will pulsate. If the holes are too far opened, too little media will go to the gun and production will decrease. 5.7 Nozzle Size - By changing to the next larger size of air jet and nozzle, production can increase significantly. Larger sized nozzles produce a larger cleaning pattern. This, however, requires more air (your compressor must be able to provide this, see chart page9) 6. MAINTENANCE INSTRUCTIONS 6.1 Blasting Gun - After 10-12 hours of blasting time, the nozzle should be checked. If it shows uneven wear it should be turned 1/4 turn every 10 hours of use. 6.2 Caking of media - Media caking is caused by moisture in the air supply or from oily and greasy parts. If this is not corrected media will not flow evenly and will plug up in the metering valve and the gun. Check air supply; if water is present install a good moisture trap. (Mod-u-blast dealers carry equipment to solve this). If oily or greasy parts are being blasted, you should apply a degreaser and dry the parts first. 6.3 Reverse pressure - If media stops flowing occasionally, place GLOVED thumb over nozzle (hold tight) and push foot pedal down for a couple of seconds. This will cause the system to back blast through the gun and up the media hose. This will help loosen any clogs. 6.4 Gun air pressure drop - Set the air pressure to 80 psi on the air gauge at regulator. Push the foot pedal while holding gun and see if the gauge pressure drops significantly. If the pressure drops, this indicates that there is a restriction is the supply line. This could be hose that is too small, a reducer or quick coupler, a plugged filter, or other piping that doesn't allow enough air through. Also if the cabinet is too far from the air compressor, a pressure drop will occur. Air supply line should be ½" or larger. Check chart pg 9. 7
6.5 Poor visibility-excessive dust: - Air inlet at front left above regulator, should be free to allow air into cabinet. - Dust container full and needs to be cleaned and emptied. (latch at bottom of dust collector or remove black cover on vacuum. - Dust cartridge contaminated. (clean or replace filter in dust collector, part # 16565, or in vacuum, part #16546) - Media breakdown; Eventually the media becomes so small that it is essentially dust. Replace media and clean dust collector. 6.6 Poor visibility-viewing window Mod-u-blast windows come with a clear plastic protector on them. As these become pitted they can be easily replaced to extend the life of the window. Order them through your dealer; part #41117 (pack of 25) or 41117s for singles. The window can also be easily replaced (part #12216). 6.7 Poor media flow - Check for moisture as indicated above. Install moisture trap as needed, Replace damp media and clean hoses and sump. - Holes in media hose will cause poor media delivery. Replace hose. - Worn nozzle. As the nozzle wears, the venturi effect, which sucks the media into the gun stops working. Replace nozzles that are worn 1/16" lager diameter than when purchased. If the nozzle and air jet are not matched correctly this will also happen (use a #5 nozzle with a #5 air jet). Size of air jet is stamped on the nut section. Size of nozzle is indicated on chart on page 9. - Debris in media. Replace or screen media. 8
7. SUPPLY AIR PIPE SIZE in inches LINE VOLUME OF AIR THROUGH PIPE (cfm) LENGTH 25 30 35 40 50 60 70 80 100 125 25'.75.75.75.75 1 1 1 1.25 1.25 1.25 50'.75.75.75 1 1 1 1 1.25 1.25 1.25 75'.75.75 1 1 1 1 1 1.25 1.25 1.25 100'.75.75 1 1 1 1 1.25 1.25 1.25 1.25 150'.75 1 1 1 1 1.25 1.25 1.5 1.5 1.5 200' 1 1 1 1 1 1.25 1.25 1.5 1.5 1.5 250' 1 1 1 1 1 1.25 1.25 1.5 1.5 1.5 300' 1 1 1 1 1 1.25 1.25 1.5 1.5 1.5 AIR REQUIREMENTS Running at 80 psi NOZZLE & AIR JET NOZZLE AIR JET No SIZE in. SIZE in. AIR REQUIRED (CFM) 3.5 3/32 *** 15.0 4 1/8 1/4 21.0 5 5/32 5/16 31.9 6 3/16 3/8 47.0 7 7/32 7/16 62.0 8 1/4 ½ 85.7 *** Use a #4 nozzle (1/4") 9
8.MAINTAIN SUCTION EFFICIENCY WITH SIMPLE STEPS The most common problem customers have with their suction (venturi) blast cabinets is a decrease in production rates. A properly maintained suction cabinet should provide years of constant service. When production rates fall the operator can usually locate the problem by checking each of the system's main components. 8.1 Air supply - If the pressure gauge on the regulator shows an adequate no-load supply (when the blaster is not running), press the foot pedal. If the pressure drops more than a few psi your air supply is restricted or inadequate. Clean filters and moisture separators all the way back to the air compressor. Straighten any kinked lines. Use a master gauge to check the air pressure or replace existing gauge if you suspect it is giving you false readings. 8.2 Blast gun - The nozzle will wear out eventually. Replace it if it measures 1/16" over its original size or if it shows uneven wear. For mod-u-blast #5 or #6 guns, adjust the air jet so that three threads (approximately 5/16") shows behind the brass locking nut. For a #3.5 or 4, adjust the air jet all the way in. Adjust as needed for different medias and conditions. 8.3 Dust collector - Inadequate cabinet ventilation results in reduced cleaning power at the nozzle as well as diminished view of the work in progress. Use the dust collectors shaker every 20-30 minutes when the cabinet is turned off, (more often in dusty conditions. Empty dust collector at least once a day. Remove filter and blow out occasionally to keep the dust collector or vacuum working efficiently. Replace as needed. 8.4 Media - Use quality blast media sized to the job. Damp or dirty media can bring blasting to an instant halt. Store media in a dry area and load the appropriate quantity. Approximately 1/4 bag. If you run out of media as you are blasting add enough so it keeps circulating to the gun. The media will eventually break down or get too contaminated to use. The less there is in the system, the less you will have to replace. 8.5 Media delivery -Replace any media hose that has soft spots or visible wear. Adjust the metering valve to provide adequate flow. A mixture that is too rich will cause pulsating at the gun. An unusually loud noise while blasting means the mixture is too lean. A rich mixture can result in lower impact velocities, while a lean mixture reduces the number of impacts. Both reduce your cleaning rate. If everything is adjusted right and you are still not getting the production levels needed, contact your distributor. The suction system may be operating properly, it may be time to get a cabinet with a media reclaimer or a pressure system. Many upgrades are available. 10
PEENING / BIG BEADS Remove larger, tougher soils: Fewer impacts per pound: Cleans slower; Peen to more intensive levels; Can't reach small areas; Produce higher surface RMS or AA; Peen deeper zone in surface; *Produces brighter finish at same intensities as smaller beads; Consume faster at same pressure as small beads; In practice may consume slower than small beads, as less pressure required to accomplish work; As large as 4 mm diameter (RMS:Root Mean Square) (AA:Arithmetic Average) GLASS BEAD FACTS CLEANING / SMALL BEADS Remove smaller, lighter soils; More impacts per pound; Cleans faster; Peens to less intense levels; Reach into keyways, fillets, small areas; Produces lower surface RMS or AA; Peen outer zones on surface; *Produces more matte finish at same intensities as large beads; Consume slower at same pressure as large beads; In practice may consume faster than large beads, as more pressure required to accomplish work; As small as 37 microns and finer FINISHING / ALL BEADS Peen to higher intensities at 90 degree nozzle angle; Consume greater at 90 degree nozzle angle; Consume greater at higher blast pressure; Consume greater as workpiece hardness increases; Consume greater as nozzle approaches workpiece; Clean less efficiently at 90 degree nozzle angle, due to narrowing of blast pattern area and "binding" by rebounding beads; Glass bead is inert, contains no free silica (not a silicosis hazard like silica sand) and is easily and safely disposed of. **NOTE** Factors affecting final surface appearance, as well as consumption rate include shape, composition, and hardness of workpiece, bead size, angle of nozzle, distance of nozzle from surface, air pressure and type of delivery system (suction verses pressure blast). GLASS BEAD ORDERING INFORMATION STOCK No. DESCRIPTION SIZE 71003 #3 (20-30 mesh) glass bead 20 Kg 71004 #4 (30-40 mesh) glass bead 20 Kg 71005 #5 (40-50 mesh) glass bead 20 Kg 71006 #6 (50-70 mesh) glass bead 20 Kg 71007 #7 (60-80 mesh) glass bead 20 Kg STOCK No. DESCRIPTION SIZE 71010 #10 (100-170 mesh) glass bead 20Kg 71011 #11 (120-200 mesh) glass bead 20 Kg 71012 #13 (170-325 mesh) glass bead 20 Kg 71100 MGA MANUS Glass abrasive 20 Kg 71108 MGG MANUS Glass grit 20 Kg 71008 #8 (70-100 mesh)glass bead 20 Kg 11
E SERIES CABINET PARTS LIST MOD-U-BLAST 1 18 2 17 3 16 4 15 5 6 14 8 9 10 7 13 12 11 12
ITEM PART # DESCRIPTION E SERIES PARTS LIST 1 ZW-LAMPX LAMP HOUSING 2 16372 LAMP FIXTURE 2 BULB 3 16370 FLOURESCENT TUBES 4 12215A WINDOW FOR LAMP 43518S SINGLE WINDOW PROTECTOR 5 16540 TRIM LOK WINDOW SEAL 6 12434 DOOR GASKET 7 Z-LATCH DOOR LATCH 8 55-415 1/4" PRESSURE GAUGE 9 50-330 3/8" REGULATOR STEL03 3/8" STREET ELBOW 11724 3/8" X ½" BARB ADAPTER 10 12-PUSH ½" PUSH ON AIR HOSE 12-MED ½" CLEAR MEDIA HOSE 11 16190 -M 1/2" FOOT PEDAL COMPLETE 16183 1/2" FOOT PEDAL VALVE ONLY 12 12011 METERING VALVE PLUG 13 16025 METERING VALVE 14 12535 8" GLOVE CLAMP 15 15250 GLOVES PAIR 16 16053 WINDOW FRAME COVER 17 12216 SAFETY WINDOW 41117S SINGLE WINDOW PROTECTOR 18 16540 TRIM LOK WINDOW SEAL PART# 43518 LAMP PROTECTORS (PACKAGE OF 25) PART# 41117 WINDOW PROTECTORS (PACKAGE OF 25) 13
SUCTION GUN ASSEMBLY SUCTION GUN ASSEMBLY PARTS LIST ITEM PART # DESCRIPTION 1 11914 NOZZLE HOLDING NUT BRASS 2 36664 #4 CERAMIC NOZZLE (STANDARD) 36665 #5 CERAMIC NOZZLE 36666 #6 CERAMIC NOZZLE 36667 #7 CERAMIC NOZZLE 37664 #4 TUNGSTEN NOZZLE 37665 #5 TUNGSTEN NOZZLE 37666 #6 TUNGSTEN NOZZLE 14
SUCTION GUN ASSEMBLY PARTS LIST 35934 #4 BORON NOZZLE 35935 #5 BORON NOZZLE 35936 #6 BORON NOZZLE 3 12031 NOZZLE O RING (EACH) 4 11802 VACU-BLAST GUN BODY ONLY 5 11913 AIR JET HEX NUT BRASS 6 11913 AIR JET SLEEVE 7 12341 # 3.5 AIR JET 12342 # 4 AIR JET 12343 # 5 AIR JET 12344 # 6 AIR JET 12345 # 7 AIR JET 12346 # 8 AIR JET 12348 # 3 AIR JET 8 11723 3/8" SWIVEL FITTING AIR INLET 9 11724 3/8" LOCK BARB FITTING MEDIA INLET 10 12-MED ½" CLEAR MEDIA HOSE 11 12-PUSH ½" PUSH ON AIR HOSE COMPLETE GUN ASSEMBLIES 12300 #3.5 GUN ASSEMBLY CERAMIC 12301 #4 GUN ASSEMBLY CERAMIC 12302 #5 GUN ASSEMBLY CERAMIC 12303 #6 GUN ASSEMBLY CERAMIC 12304 #7 GUN ASSEMBLY CERAMIC 12301T #4 GUN ASSEMBLY TUNGSTEN CARBIDE 12302T #5 GUN ASSEMBLY TUNGSTEN CARBIDE 12303T #6 GUN ASSEMBLY TUNGSTEN CARBIDE 12302B #6 GUN ASSEMBLY BORON CARBIDE 12303B #6 GUN ASSEMBLY BORON CARBIDE 15
E SERIES DUST COLLECTORS PART # DESCRIPTION 16545 SHOP-VAC COMPLETE 16546 SHOP-VAC REPLACEMENT FILTER 16550R-P E SERIES DUST COLLECTOR COMPLETE 16560 REPLACEMENT VACUUM MOTOR FOR (16550R-P) 16565 E SERIES D.C. REPLACEMENT FILTER 16
E SERIES PNEUMATIC DIAGRAM 17
E SERIES ELECTRICAL DIAGRAM 18
19