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500 E Global

Operating Instructions

Fault diagnosis

5

Fault Possible

cause Remedy

Control
system
switches off
during
operation

Connection cable is
defective.

Cables connecting the
units (travel motor, etc.)
are defective.

Motor protection
switches have triggered.

Main switch of the filter
unit switches of due to
overload.

Replace the cable.

Replace 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 motor
lead or tachometer lead,
motor defective.

Control unit defective.

Potentiometer defective.

Have the unit checked by
an electrician.

Replace the control unit.

Replace the
potentiometer.

Note: If the motor protection switch of the blast wheel motor has
been triggered by overload, it can be switched on again after a short
cooling down period.

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Содержание 500 E Global

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

Страница 2: ......

Страница 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...

Страница 4: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

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

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

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

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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...

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

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

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

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