Blastrac 500 E Global Operating Instructions Manual Download Page 9

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500 E Global

Operating Instructions

Safety instructions

Contents Chapter 2

2.0 Warnings and symbols

2.1 Organisational

measures

2.2 Personnel

selection and qualification

2.3 Safety precautions applicable to different operating conditions

2.4 Special work within the scope of use of the equipment and

maintenance activities as well as repairs during operation

2.5 Definition of the

Safety off position

2.6 Particular dangerous aspects of the equipment

2.7 Electrical

engineering regulations

Summary of Contents for 500 E Global

Page 1: ...Operating Instructions 500 E Global MAN 500E Global EN REV 0...

Page 2: ......

Page 3: ...intenance Electrical systems Fault diagnosis Spare parts Design and specifications are subject to change without notice April 2005 Blastrac BV Utrechthaven 12 3433 PN Nieuwegein THE NETHERLANDS T 31 0...

Page 4: ......

Page 5: ...s Technical data 1 Contents Chapter 1 1 1 Rating 1 2 Unit specifications 1 3 Operative range and correct usage 1 4 Stand by power supply generator 60 Hz 1 5 Machine type designation 1 6 Advice for ope...

Page 6: ...bal Length 1560 mm Width 750 mm Height 1650 mm Weight ca 650 kg Connected loads electrical system The indicated input current values correspond to the nominal current values of the motors working unde...

Page 7: ...o 75 m h Dust hose connection 150 mm Recommended abrasive Shot 390 460 SG18 16 14 Abrasive consumption 0 1 0 5 kg m Recommended filter unit Contact Blastrac for a suitable Blastrac filter unit 1 3 Ope...

Page 8: ...liminate possible damage to electrical components 1 5 Machine type designation 1 6 Advise for operators of blast cleaning machines In accordance with the accident prevention regulations for blast clea...

Page 9: ...lection and qualification 2 3 Safety precautions applicable to different operating conditions 2 4 Special work within the scope of use of the equipment and maintenance activities as well as repairs du...

Page 10: ...e shown next to all safety precautions that are to be taken in order to ensure prevention to life and injury Follow these instructions and take special care in these circumstances In addition to these...

Page 11: ...ting Instructions 2 1 Organisational measures The Operating Instructions are to be kept near the location where the machine is located and must be within reach at all times In addition to the Operatin...

Page 12: ...hing or jewellery including rings There is a risk of injury through getting stuck or being drawn into moving machinery Use personnel protection equipment if necessary or required by regulations Take n...

Page 13: ...aken by reliable personnel Only trained personnel may be deployed Note the statutory minimum age Specify clearly the responsibilities of personnel for operation setting up servicing and maintenance wo...

Page 14: ...and the fault must be rectified Secure the work area around the machine in public areas providing a safety distance of at least 2 m from the machine Before switching on the machine make sure that no...

Page 15: ...ement of parts and equipment must be undertaken and or complied with These activities may only be undertaken by qualified personnel Do not use any aggressive cleaning materials Use lint free cleaning...

Page 16: ...fety off position Definition The machine is in a safe condition when it cannot generate any hazard Putting the equipment in the Safety off position means Close the valve Switch off the blast machine S...

Page 17: ...afety regulations during operation and maintenance of safety devices supplied with the machine as well as the provision of appropriate additional safety devices 1 Blast housing outlet Danger of injury...

Page 18: ...t must inspected regularly Please note in particular the specified recurring inspections according EN60204 1 Defects such as loose connections or scorched cables must be rectified immediately Call a s...

Page 19: ...3 2 Operating instructions 3 3 Connections 3 4 Care and maintenance 3 5 Scope of supply 3 6 Description 3 7 Control box 3 8 Operating elements 3 9 Blast wheel 3 10 Separator and hopper 3 11 Drive sys...

Page 20: ...herefore it is important that all persons operating and maintaining the machine read this manual carefully and understand it fully The supplied machine has been manufactured for being employed in the...

Page 21: ...Connection type 500 E Global 400 480V 60Hz 63A 3 4 Care and maintenance Special attendance and regular maintenance of the machine and its parts are imperative for functioning and safety In order to p...

Page 22: ...hine 500 E Global Dust hose Operating instructions 2 x Maintenance box option Magnetic broom option 3 6 Description Fig 3 1 1 Fan unit 6 Blast housing 2 Abrasive separator 7 Recovery duct 3 Control bo...

Page 23: ...cal pre acceleration the abrasive is thrown onto the surface at high speed by the blast wheel Once the abrasive has impacted on the surface it rebounds into a recovery duct The recovery duct deflects...

Page 24: ...ed control 13 Main switch 4 Tracking control 14 Control lamp voltage 5 Right motor STOP 15 Control lamp Main blast 6 Drive wheel joystick right 16 Push button Fan ON 7 Emergency shutdown switch 17 Pus...

Page 25: ...he machine fan on An airflow is generated from the blast head towards the filter unit Pressing the push button Fan OFF switches the machine fan off Push buttons Main blast ON OFF Before pressing this...

Page 26: ...ed by the blast wheel 3 8 Operating elements The shot valve Between the abrasive storage hopper and the blast housing there is a valve in order to control the abrasive flow towards the blast wheel Any...

Page 27: ...he right side of the hopper and regulates the shot valve to control the flow of abrasive towards the blast wheel When the handle is pulled upwards the shot valve is opened and abrasive is allowed to t...

Page 28: ...ined with replaceable wear parts The blast wheel is driven by an electric motor Fig 3 6 Around the centre of the blast wheel there is the impeller feeding dosed quantities of abrasive onto the blades...

Page 29: ...eparator is mounted to the end of the recovery duct It separates the abrasive from contaminants and feeds the cleaned abrasive onto the abrasive storage hopper Fig 3 7 1 Separator 2 Baffle plates 3 Ho...

Page 30: ...tem The drive is an independent electric system contained within the V of the blast housing cabinet There is an On Off switch on the electrical panel to operate this drive control system Fig 3 8 1 Con...

Page 31: ...the front side of the machine until the rear of the blast wheel motor rests on the work surface Important note to prevent injury lock the front side of the machine with a wooden block 2 Unscrew the bo...

Page 32: ...cessary Fig 3 10 1 Side brush 2 Side skirt fixing plate 3 Side skirt 4 Seal box blast housing 5 Side seal spring 6 Side seal spring plate 7 Side seal Method of installing side seals It is necessary to...

Page 33: ...ard and down the ramp At the same time the side seal will fully locate into the seal box Check that both axles of the side seal spring plate have come out at the top of the seal box to be sure that th...

Page 34: ...ust to the filter unit Machine fan Motor output 2 2 kW Air throughput 1200 m h Dust hose Length 20 m standard up to max 60 m Diameter 150 mm All connection points must be sealed carefully and the dust...

Page 35: ...abrasive and transports the dust to the outlet opening The separator door must be closed airtight in order to grant an optimum performance of the separator The air stream then flows through the appro...

Page 36: ...sive The machine 500 E Global has been especially designed to be operated with Blastrac abrasive The Blastrac abrasive is of very high quality and owns the rebouncing ability required for the efficien...

Page 37: ...and cleaning of steel surfaces Abrasive shot S460 with SG18 16 14 For removal of coatings from steel surfaces mix approx 75 S460 shot with 25 SG grit The type of grit is depending on the profile requi...

Page 38: ...used Please take into account that the use of incorrect abrasive increases wear Our service engineers have the experience to select the appropriate abrasive for the individual cases of application Pl...

Page 39: ...500 E Global Operating Instructions Transport 1 Contents Chapter 4 4 1 General notes 4 2 Transport 4 3 Operation conditions 4 4 Operation 4 5 Unit specifications...

Page 40: ...ersonnel not trained by Blastrac BV 4 2 Transport When transporting the machine proceed in such a manner that damage due to the effects of the use of force or incorrect loading and unloading is avoide...

Page 41: ...es like weld seams or floor joints are no barriers for the machine 4 4 Operation The machine is operated in accordance with the instructions given in Chapter 5 Initial operation Whenever the machine i...

Page 42: ...Operating Instructions 500 E Global Transport 4...

Page 43: ...500 E Global Operating Instructions Initial operation 1 Contents Chapter 5 5 1 Preparations for initial operation 5 2 Initial operation...

Page 44: ...that the machine can travel over all inequalities on the surface Small inequalities like weld seams or floor joints are no barriers for the machine Regular inspection is important in order to avoid d...

Page 45: ...ants Check the level of abrasive in the storage hopper Refill if necessary Before start up the operating personnel must be familiar with the safety regulations given in this manual Check the main powe...

Page 46: ...as been emptied 5 2 Initial operation All persons in the proximity of the machine must wear ear protectors safety glasses with lateral protection as well as safety shoes The operator is obliged to wea...

Page 47: ...n Fan ON Press the push button Main blast ON The blast wheel motor is started Observe the ammeter in order to check the power consumption of the blast wheel motor The motor requires a lot of power sta...

Page 48: ...aning concrete the abrasive shot valve may only be opened when the blast cleaning machine is travelling If the machine is at a standstill and the shot valve is open deep holes may be blasted into the...

Page 49: ...abrasive shot valve stop the machine and check the blasted surface If the blast pattern is irregular it may be necessary to re adjust the blast pattern see Chapter 7 5 Setting the blast pattern or sel...

Page 50: ...Operating Instructions 500 E Global Initial operation 8...

Page 51: ...Contents Chapter 6 6 1 Operation 6 2 Electric drive system 6 3 Recommended blast paths 6 4 Switching off the machine 6 5 What to do if a fault occurs 6 6 Safety shutdown 6 7 Restarting after a fault...

Page 52: ...unit Make sure that no vehicles such as forklift trucks and other equipment run over the electric cable and the dust hose The selection of the correct advancing speed of the blast machine is important...

Page 53: ...travels straight For quicker response during higher speeds there are two wheel motor stop buttons Pressing either of these will stop the wheel motor to which is connected This will give quick respons...

Page 54: ...ut the hose as shown in fig 6 1 Work with the blast cleaning machine with the hose spread out in the opposite direction repeating the process away from the filter unit Fig 6 1 1 Filter unit 2 Dust hos...

Page 55: ...r Press the push button Fan OFF This switches off the fan motor Set the main switch on the main box at the front of the blast cleaning machine to OFF After several minutes press the push buttons Compr...

Page 56: ...afety off position After that start looking for the defect 6 6 Safety shutdown The machine must be put to its safety off position before starting repair works See Chapter 2 Safety instructions 6 7 Res...

Page 57: ...ore a long standstill period Switch off the machine see Chapter 6 4 Protect the electric motors from moisture heat dust and shocks Clean the machine and cover it with a plastic foil Preserve bright pa...

Page 58: ...Operating Instructions 500 E Global Operation 8...

Page 59: ...ontents Chapter 7 7 1 Recommendations 7 2 Maintenance and inspection list 7 3 Repairing 7 4 The blast pattern 7 5 Setting the blast pattern 7 6 Setting the control cage 7 7 Wear parts 7 8 Blastwheel b...

Page 60: ...ninterrupted operation When the indicated number of working hours is not achieved during the corresponding period the period can be extended However a full overhaul must be carried out at least once a...

Page 61: ...ments of dirt or foreign bodies Check the electric motors for dirt and other contaminants daily and prior to starting work Check the hose connections for tightness and fixed seat Check the hose to the...

Page 62: ...required to replace wear parts If you replace parts yourself for specific reasons the following instructions and work sequence have to be observed You should also stock all spare or wear parts that c...

Page 63: ...t of the control cage and thus of the blast pattern is the most important factor for optimum working with the 500 E Global blast cleaning machine Incorrect adjustment of the control cage results in ve...

Page 64: ...d The blast wheel motor is designed for a long service life Damages to the blast wheel motor can be detected by unusual noises or functional failure of the electric motor In this case notify our servi...

Page 65: ...e of the abrasive affects the blast pattern With every exchange of abrasive the blast pattern must be re adjusted Position of the control cage The correct adjustment of the control cage is the most im...

Page 66: ...heir different weights and frictional resistance This means that you must never use different types of abrasive at the same time The adjustment can be carried out as follows Determine the notches whic...

Page 67: ...oking from the front side of the machine onto the control cage If the left side of the blasted area is warmer turn the upper edge of the control cage anti clockwise for 3 6 mm If the right side is war...

Page 68: ...Operating Instructions 500 E Global Maintenance 10 7 7 Wear parts The blast wheel parts Fig 7 3 1 Cage clamp 2 Control cage 3 Impeller 4 Blades set of 6 5 Blast wheel...

Page 69: ...500 E Global Operating Instructions Maintenance 11 The liners Fig 7 4 1 Top liner 2 Right liner 3 Left liner...

Page 70: ...move the impeller using a wooden or brass drift Remove the top liner cover and remove the top liner using a screwdriver or a crowbar Clean the blast wheel and the blades with air Through the opening a...

Page 71: ...right hand liners and take the side liners out of the blast housing Replace all worn items Clean the liners and the inside of the blast housing thoroughly Re assemble the machine in reverse order usin...

Page 72: ...Operating Instructions 500 E Global Maintenance 14...

Page 73: ...500 E Global Operating Instructions Electrical systems 1 Contents Chapter 8 8 1 Electric circuit diagrams...

Page 74: ...Operating Instructions EBE 500 E Electrical systems 2...

Page 75: ...500 E Global Operating Instructions Electrical systems 3 8 1 Electric circuit diagrams...

Page 76: ...Operating Instructions EBE 500 E Electrical systems 4...

Page 77: ...2566T1A 7 8 Pages 13 Page 9 2 1 PROJECT Client Name SUPPLIER Draw number Order number DATA Arch number Calc number Status Start of project Latest change USF EBE B V 500 SB UL PJ05 02566T1A PJ05 02566T...

Page 78: ...ge By X 1 2 3 4 5 6 7 8 9 10 11 12 13 Frontpage Contents Wiring dates Wiring dates Switch cabinet summary Main Voltage Main Voltage Main Voltage Control Voltage Terminal strip X0 Connector Left Motor...

Page 79: ...s Built USF EBE B V 500 SB UL 2 3 4 Wiring dates 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 4 3 Wire Color Main Voltage L1 L2 L3 N PE Control Voltage 24VAC A 24VAC B Black Bla...

Page 80: ...rgency stop NC Contact NO NC Thermal Key switch NO NC Thermostat NO NC P A V M 3 P Pressure switch NO NC Level switch NO NC Relay Relay Time delayed on drop out Relay Time delayed on pick up Relay Imp...

Page 81: ...tart Eng Print Status 1 07 02 2005 RJO 07 12 2005 As Built USF EBE B V 500 SB UL 2 3 4 Switch cabinet summary 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 6 5 7U2 6T1 7U1 7L1 7L...

Page 82: ...L1 U 16 CON3 1 M 3 6M2 U1 W2 V1 U2 W1 V2 Blaster 18 5kW 36A 17 6T1 18 19 L2 V 20 2 21 L3 W 22 3 PE PE A 6P1 1 2 A1 25 9 6 A1 25 IN2 25 6 13 4 1 14 26 9 7 14 5 3 A2 33 9 6 A2 5 IN1 28 9 7 IN1 4 0 6 3A...

Page 83: ...6 6 9KM2 L1 6 6 9KM2 L2 6 7 9KM2 L3 7L1 EZN3A1500H003 7U1 Lenze E82EV751 48200 L1 L1 1 36 L1 U 37 CON1 1 M 3 7M1 U V W Left Motor L2 L2 1 39 L2 V 40 2 L3 L3 1 42 L3 W 43 3 44 PE PE 1 4 PTC T1 T2 PTC 5...

Page 84: ...Pages 13 Page 9 9 8 7 9 9KM2 L1 7 9 9KM2 L2 7 9 9KM2 L3 56 59 62 8L1 EZN3A1500H003 8U1 Lenze E82EV751 48200 L1 L1 1 57 L1 U 58 CON2 1 M 3 8M1 U V W Right Motor L2 L2 1 60 L2 V 61 2 L3 L3 1 63 L3 W 64...

Page 85: ...resent 33 Start fan 9S2 13 14 76 Stop fan 9S3 11 12 77 6Q1 6 5 13 14 78 1 2 6 4 3 4 6 5 5 6 6 5 13 14 9 2 9KM1 A1 A2 Fan 75 33 9KM1 9 2 13 14 76 78 gn 9H2 X1 X2 Fan Start drive 9S6 13 14 101 Stop driv...

Page 86: ...KU 07 12 2005 As Built USF EBE B V 500 SB UL 2 3 4 Terminal strip X0 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 11 10 Internal connection Bridges Terminal X0 6W1 6QM1 1 1 1 L1...

Page 87: ...E B V 500 SB UL 2 3 4 Connector Left Motor 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 12 11 Internal connection Bridges Terminal CON1 7M1 7U1 U 1 1 U Left Motor 1 7U1 V 2 2 V...

Page 88: ...BE B V 500 SB UL 2 3 4 Connector Right Motor 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 13 12 Internal connection Bridges Terminal CON2 8M1 8U1 U 1 1 U Right Motor 1 8U1 V 2 2...

Page 89: ...V 500 SB UL 2 3 4 Blaster 5 6 Arch nr Draw nr PJ05 02566T1A PJ05 02566T1A 7 8 Pages 13 Page 9 13 Internal connection Bridges Terminal CON3 6M2 6U1 U 1 1 U1 Blaster 1 CON3 5 6U1 V 2 2 V1 2 CON3 6 6U1 W...

Page 90: ...Operating Instructions EBE 500 E Electrical systems 18...

Page 91: ...500 E Global Operating Instructions Fault diagnosis 1 Contents Chapter 9 9 1 Fault diagnosis blast machine 9 2 Fault diagnosis electrical system...

Page 92: ...en parts from the machine Replace the worn fan impeller Unusual noise Too little play or poor alignment of the rotating parts Loose and incorrect set screws Squeaking wheels Seizing motor Check alignm...

Page 93: ...y Check the adjustment of the valve Close the shot valve and stop the blast wheel motor Start the blast process again and slowly open the valve Reduce the travel speed Escaping abrasive Poor sealing C...

Page 94: ...be blasted Adjust the blast pattern Machine is not moving The travel speed is too low Increase the travel speed 9 2 Fault diagnosis electrical system Prior to any repair works on the machine or its d...

Page 95: ...ce the cable Have the fault checked by an electrician Switch the main switch ON with fault have the unit checked by an electrician Machine does not travel Fuse defective or short circuit in the travel...

Page 96: ...Operating Instructions 500 E Global Fault diagnosis 6...

Page 97: ...500 E Global Operating Instructions Spare parts 1 Contents Chapter 10 10 1 Spare parts...

Page 98: ...0 1053 SE Front skirt intermediate 1 6 500 1057 SE Front skirt fixing plate 1 7 500 1052 SE Front skirt inner 1 8 500 2010 SEH Front wheel castor 1 9 500 1020 Side seal set of 2 1 10 500 1021 SE Side...

Page 99: ...500 E Global Operating Instructions Spare parts 3 10 1 Spare parts Fig 10 1...

Page 100: ...ion Qty 1 500 1245 Impeller bolt 1 2 500 9041 SEVU Control cage clamp 2 3 500 1010 Control cage 1 4 500 1015 Impeller 1 5 500 1025 Blastwheel 1 6 500 1005 Blades set of 6 1 7 222 2265 Taperlock adapte...

Page 101: ...0 9118 SE Baffle plates 1 4 500 9121 SE Separator deflector 1 5 E00992 Abrasive storage hopper 1 6 600 9240 Shot valve axle housing 1 7 500 1071 Shot valve insert steel 2 8 500 1070 Shot valve insert...

Page 102: ...Operating Instructions 500 E Global Spare parts 6 Fig 10 3...

Page 103: ...art no Description Qty 1 500 3055 SHEV Fan motor 2 2 kW 1 2 500 9030 Fan housing plate top 1 3 500 1085 Fan impeller 1 4 500 1090 Fan housing 1 5 500 1120 Fan housing elbow 1 6 500 9025 Fan housing pl...

Page 104: ...erating Instructions 500 E Global Spare parts 8 Recovery duct Fig 10 5 Fig 10 5 Item Part no Description Qty 1 E03509 Recovery duct 500E Global 1 2 E03191 Weight box 1 3 E03185 Weight for 500E Global...

Page 105: ...e Fig 10 6 Fig 10 6 Item Part no Description Qty 1 E00286 Control box 500E 1 2 E03184 Control handle 1 3 500 9007 SEVU Motor adaption plate 1 4 E00963 Blast motor parallel key 1 5 500 3020 SHEV Blast...

Page 106: ...Operating Instructions 500 E Global Spare parts 10...

Page 107: ...ft 1 5 500 9131 E Drive motor plate inner left 1 6 500 9130 E Drive motor plate outer right 1 7 500 9132 E Drive motor plate inner right 1 8 500 2425 E Drive wheel 2 9 500 1135 E Bearing flange drive...

Page 108: ...Operating Instructions 500 E Global Spare parts 12 Fig 10 7...

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