Blastrac 1-7D Operating Instructions Manual

change without notice - September 1999 ISPC Blastrac/EBE Utrechthaven 12 3433 PN Nieuwegein THE NETHERLANDS T +31(0)30 - 601 88 66 F +31(0)30 - 601 83 33 E [email protected] I www.surfacepreparation.com Nieuwegein

1.1 Rating 1.2 Unit specifications 1.3 Operative range and correct usage 1.4 Machine type designation 1

: ISPC Blastrac/EBE blast cleaning machine Machine type : 1-7D Manufacturer : ISPC Blastrac/EBE Utrechthaven 12 NL-3433PN Nieuwegein THE NETHERLANDS 1.2 Unit specifications Dimensions: 1-7D Length 1040 mm Width 310 mm Height 980 mm Weight 48 kg Connected loads (electrical system): The indicated input current values correspond to the nominal current values of the motors working under full load. These values are not achieved under normal operating conditions. 1-7D Power consumption Input current Blast wheel drive 2,5 kW max. 16 A Filter unit 3,0 kW max. 16 A Electrical connection required : 230 V, 50 Hz, 16 A, plug 230V 2

: 165 mm Ø Working width : 200 mm Drive speed : manual driven Blast cleaning output on concrete : up to 15 m²/h Dust hose connection : 50 mm Ø Recommended abrasive : Media No. 2 - No. 4 Abrasive consumption : 100 g/m² Recommended filter unit : 317 DC 1.3 Operative range and correct usage The 1-7D is exclusively designed to clean dry, frost- free horizontal surfaces. The machine may not be used for other purposes. The manufacturer will not be liable for damage resulting from such incorrect usage. In these cases the user assumes all risks. 1.4 Machine type designation number of blast wheels blast cleaning width product code 1 - 7 D 3

2.1 Warnings and symbols 2.2 Organisational measures 2.3 Personnel selection and qualification 2.4 Safety precautions applicable to different operating conditions 2.5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation 2.6 Definition of the Safety off position 2.7 Particular dangerous aspects of the equipment 2.8 Electrical engineering regulations 1

The following denominations and symbols are used in the Operating Instructions to highlight areas of particular importance: Symbol of operational safety. In these Operating Instructions this symbol will be 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 instructions, the general safety precautions and accident prevention guidelines are also to be followed. Particular details regarding the economical use of the equipment. Information, instructions and restrictions with regard to possible risks to persons or to extensive material damages. 2

Indications relating to protective devices in electrical appliances. Indications where consultation with the manufacturer is required. Instructions relating to periodical checks. Reference to important instructions contained in the Operating Instructions. 3

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 Operating Instructions general and legal regulations regarding accident prevention and environmental protection must be complied with and indicated! Such duties may for example relate to the handling of hazardous substances or to the provision and wearing of personal protection equipment as well as compliance with traffic regulations. The Operating Instructions must be supplemented by instructions including the duty to supervise and report relating to particular working practices, for example work organisation, work procedures and personnel allocation. Personnel entrusted with working with the machine must have read the Operating Instructions before starting work, in particular the Safety Instructions chapter. To read these instructions during work is too late. This particularly applies to incidental activities such as setting up the equipment, carrying out maintenance work or training staff to work with the machine. From time to time the working practices of the staff are to be checked regarding awareness of safety and hazards. Personnel must tie back long hair and not wear loose clothing 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 notice of all safety and hazard notices on the machine! All safety and hazard notices at or on the machine must be kept complete and legible! 4

method, the machine must be shut down immediately! The cause of the fault must be established immediately! Changes, add-ons or conversions to the machine which might impair safety must not be undertaken without the manufacturer’s permission! This applies in particular to the fitting and adjustment of safety devices as well as to welding on load-bearing parts. Spare parts must comply with the technical requirements specified by the manufacturer. This is always guaranteed if original spare parts are used. Intervals for recurring checks and inspections specified in these Operating Instructions must be complied with! To perform maintenance work correctly it is imperative to be equipped with the proper tools for the task in question. The location and the operation of fire extinguishers must be made known on each building site! Take note of the facilities for reporting and fighting fires! 2.3 Personnel selection and qualification Fundamental duties : Work on the machine may only be undertaken 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 work! Make sure that only authorised personnel operate or work on the machine! Define responsibilities of the machine operator also regarding to traffic safety regulations and empower him to decline instructions from third parties which are not complying with the safety requirements! 5

only be deployed on the machine under constant supervision of an experienced person! Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by trained persons under the guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations. 2.4 Safety precautions applicable to different operating conditions Ban any method of working that impairs safety! Only operate the machine when all safety devices and related safety equipment, e.g. detachable safety devices, emergency stops and suction devices are present and operational! Check the machine visually for any damage and defects at least once a day! In the event of operational malfunctions the machine must be shut down immediately and secured, 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-one can be endangered when the machine starts up! Do not switch of or remove the exhaust and ventilation devices when the machine is running! All persons in the proximity of the machine must wear safety glasses with lateral protection as well as safety shoes. The operator is obliged to wear close-fitting protective clothing. 6

sized and marked in accordance with the overall power consumption of the machine and the valid VDE guidelines. 2.5 Special work within the scope of use of the equipment and maintenance activities as well as repairs during operation Mechanical servicing work: Put the machine in the Safety off position as described in chapter 2.6 for any servicing work on the machine in order to prevent the machine from being switched on accidentally. Please follow any special safety instructions in the various chapters on servicing the machine. See chapter 7.1 - 7.7. Adjustment, servicing and inspection work and time limits specified in these Operating Instructions as well as any information on the replacement 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 cloths! Always tighten any screw connections that are undone during servicing and maintenance work! If safety devices need to be dismantled during setting up, servicing and repairs, these safety devices must be reinstalled and inspected immediately after completion of the servicing and repair work. Make sure that process materials and replaced parts are disposed of safely and in an environmentally-friendly manner! Electrical servicing work: Make sure that electrical components used for replacement purposes comply with the original parts and are correctly adjusted if necessary. For safety notes see 2.8 Electrical engineering regulations. 7

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 magnetic valve. � Switch of the blast machine. � Switch off the dust collector. � Wait for standstill of all drives. � Pull out mains plug. 8

Any machine, if it is not used according the regulations, may be hazardous for operating, setting-up and service personnel. The operating authority is responsible for compliance with the safety regulations during operation and maintenance of safety devices supplied with the machine as well as the provision of appropriate additional safety devices! 1 1. Blast housing outlet Danger of injury! Abrasive leaves housing with high speed! Moving parts! Lift and cant the machine only when it is in Safety off position. It is not allowed to stay within the working radius of the machine! 2. Wheels Danger of injury! Moving parts! It is not allowed to stay within the working radius of the machine! 9

Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by trained persons under the guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations. Use only extension cable for extending the main cable that are sized and marked in accordance with the overall power consumption of the machine and the valid VDE guidelines. The electrical equipment for the plant 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 skilled electrician or our Customer Services. A second person must be deployed who can pull out the plug in an emergency if work on live parts is necessary. The work area must be sealed off using a red and white safety chain and a danger sign. Use a tool that is insulated against voltages. Only start work once you are familiar with the electrical engineering regulations that apply to your area. Only use voltage seekers that comply with the regulations when troubleshooting. From time to time check voltage seekers to ensure that they are operationally efficient. 10

3.1 Operative range 3.2 Scope of supply 3.3 Description 3.4 Operating elements 3.5 Blast wheel 3.6 Separator 3.7 Abrasive valve 3.8 Abrasive sealing 3.9 Abrasive media 3.10 Care and maintenance 1

The ISPC Blastrac/EBE blast cleaning machine 1-7D is a downward blasting machine with a closed abrasive circuit designed for the pre- treatment of horizontal surfaces. The bouncing impact of metallic abrasive onto the surface to be treated thoroughly removes surface contaminants, coats of paint, sealants and thin coatings. A suitable filter unit must be connected to the machine in order to separate the dust from the abrasive. A specially designed dust collection system ensures dust-free operation of the machine and clean air at the workspace. 3.2 Scope of supply Scope of supply of the machine: � Blast cleaning machine (1-7D) � Operating instructions (2 x) � Maintenance box (option) � Filter unit (option) � Magnetic broom (option) 2

4 Electric cable 11 Toothed washer 5 Abrasive control handle 12 Blast wheel motor 6 Limit switch 13 Control lever 7 Wheels Like many revolutionary inventions the blast wheel method is based on a simple principle: after mechanical 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 rebound plenum. The rebound plenum deflects the abrasive into an air current separator. Here dust and other contaminants are removed from the abrasive so that only abrasive containing a very small amount of dust is fed into the abrasive storage hopper for re-use by the blast wheel. 3

The abrasive control handle is located on the machine handle and regulates the magnetic valve to control the flow of abrasive towards the blast wheel. The valve is hand-operated and can be set to each amount of abrasive throughput by changing the handle position. Fig. 3.2 1 Blast wheel motor ON / OFF 1 Blast wheel motor ON / OFF This switch lever (1) below the control handle serves for controlling the blast wheel motor. Actuating the switch lever closes the power circuit to switch on the blast wheel motor. When the lever is released, the blast wheel motor switches off (dead man’s handle). 4

The heart of the blast cleaning machine is the blast wheel which throws the abrasive onto the surface to be cleaned by using centrifugal force. The blast wheel is placed in a protective housing lined with replaceable wear plates. The blast wheel is driven by an electric motor. Fig. 3.3 3 2 1 5 4 6 7 Around the centre of the blast wheel there is the impeller (4 notches) feeding dosed quantities of abrasive onto the blades of the turning blast wheel. On top of this is the control cage which, once it is carefully set, regulates the flow of abrasive. 1 Blast wheel 2 Wheel hub 3 Top liner 4 Left liner 5 Right liner 6 Control cage 7 Wheel nut 5

plenum. It separates the abrasive from contaminants and feeds the cleaned abrasive back to the abrasive circuit. Fig. 3.4 2 3 1 1 Separator 2 Separator seal 3 Separator clamp A wire mesh is fitted to prevent any coarse contaminants from getting into the blast wheel. Only remove the separator when the blast wheel motor is at a standstill and blast cleaning machine is switched off (see “Safety off position”). Fig. 3.5 1 Wire mesh 1 2 3 2 Deflector 3 Deflector support 6

Between the abrasive storage hopper and the feed spout there is a valve incorporating a permanent magnet in order to control the abrasive flow towards the blast wheel. Any change in the opening of the magnetic valve causes the amount of abrasive fed to the blast wheel to change. The valve is hand-operated and can be set to each amount of abrasive throughput by changing the handle position. The optimum blast cleaning performance is achieved when the actuating lever is pulled up to the stop and the magnetic valve is opened up to it’s vertical position. 2 3 5 1 4 Fig. 3.6 1 Feed spout 2 Magnetic valve 3 Valve lever 4 Abrasive control cable 5 Plunger 7

Magnetic seals are fitted to the front and the sides of the blast housing outlet. The blast head is surrounded by brush seals. The seals are employed to seal the blasting area in a way to avoid leakage of any abrasive. The correct height adjustment of the magnetic seals (approx. 6 mm) is very important for optimum functionability of the machine. The adjustment can be carried out by means of setting screws on the drive wheels. 4 2 3 1 Fig. 3.7 1 Front magnet 2 Side magnet 3 Brush seal (side) 4 Brush seal (front/rear) 8

In order to operate the ISPC Blastrac/EBE machine 1-7D you need hardened, spherical abrasive. The machine 1-7D has been especially designed to be operated with ISPC Blastrac/EBE abrasive. The ISPC Blastrac/EBE abrasive is of very high quality and owns the rebouncing ability required for the efficient use of model 1-7D. The selection of the abrasive is very important since this is the material to carry out the surface treatment. Fig. 3.8 Fill in abrasive here! 9

Media No. 2: Applications: � creates fine profiles, e.g. on vacuum concrete and non-glazed tiles � removes thin layers of paint Is often used when the surface is only subsequently sealed. Media No. 3: Applications: � creates a fine to medium texture on concrete � removes glazing from tiles prior to subsequently coating with antiskid floor sealings � removes old impregnations and coatings about 1 mm thick Media No. 4: Standard abrasive, suitable for about 50-60 % of all applications. Creates a medium profile on concrete. Fulfils the same purpose as Media No. 3 when a higher speed of the machine is required, e.g. on asphalt, in order to keep the thermal load low. Applications: � removes laitance from new concrete � roughening of smooth concrete or natural stone � removes coatings with a thickness of 1-3 mm and cleaning of steel surfaces 10

ensures that the abrasive can be re-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. Please consult our local ISPC Blastrac/EBE customer service department if you have any questions about the selection of the best abrasive for your blast cleaning work. ISPC Blastrac/EBE Media No. 2 - S00002 ISPC Blastrac/EBE Media No. 3 - S00003 ISPC Blastrac/EBE Media No. 4 - S00004 3.10 Care and maintenance Special attendance and regular maintenance of the machine and its parts are imperative for functioning and safety. In order to prevent unnecessary downtimes it is recommended to keep original spare and wear parts on stock as listed in the maintenance box. A list of contents of the maintenance box is provided in Chapter 10 to enable the above-mentioned work to be carried out quickly. All persons in the proximity of the machine in operation must wear safety glasses with lateral protection and safety shoes. The machine operator must wear close-fitting protective clothing. 11

4.1 General notes 4.2 Transport 4.3 Operation conditions 4.4 Operation 4.5 Unit specifications 1

Before the machine is used for the first time, ISPC Blastrac/EBE authorised dealers offer a course to familiarise maintenance and operating personnel with all elements of the machine. We are not liable for damage caused by incorrect use of the machine by personnel not trained by ISPC Blastrac/EBE. 4.2 Transport When transporting the machine with hoisting equipment like a crane or a lift, check the total weight permitted. Only use appropriate, allowed and qualified hoisting equipment. Please look in Chapter 1 to find the weight of the machine, or see the serial plate on the machine. Remove the abrasive from the machine before it is transported. By turning the machine handle the total height of the machine can be decreased. The weight and dimensions of the machine are shown in Chapter 1 "Technical data“. The machine is to be transported after being separated into: � Machine (1-7D) � Filter unit (option) � General accessories 2

Check the surface to be treated for loose parts (stones, screws, etc.). The surface must be swept if necessary. Make sure 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. 4.4 Operation The machine is operated in accordance with the instructions given in Chapter 5 ”Initial operation“. Whenever the machine is not used for blast cleaning, the abrasive valve must always be closed! Please note that the illustrations are simplified. 4.5 Unit specifications The main dimensions and unit specifications of the machine when assembled are shown in Chapter 1 "Technical data“. 3

5.1 Preparations for initial operation 5.2 Initial operation 1

Before switching on make sure that all existing protective housings are mounted and that the filter unit is connected correctly. All persons in the proximity of the machine must wear safety glasses with lateral protection as well as safety shoes. The operator is obliged to wear close-fitting protective clothing. Handle all plugs, cables, hoses and operating devices with care. Avoid any contact with live wires. Works on the electrical system must only be carried out by qualified specialists. Check the surface to be treated for loose parts (stones, screws, etc.). The surface must be swept if necessary. Make sure 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 downtimes. Carry out the following checks before any start-up: � Check whether all machine parts are assembled safely and correctly. � Check all screws and other fasteners for tight seat. � Check the abrasive storage hopper, the feed spout and the blast wheel parts for foreign bodies and remove them. � Check the blast wheel blades, impeller, control cage, liners and fastening screws for damages and wear. � Check the magnetic and brush seals for wear. 2

hours. � Make sure the dust container of the filter unit is empty. Please comply with the local waste treatment regulations considering the removed material. � Check the separator parts for wear and defects. Remove foreign bodies and dust deposits in order to prevent the separator from being blocked. � Check the electrical connections for dirt and foreign body deposits. � Check the electrical motors for dirt and other contaminants. � 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. � Place the blast cleaning machine and the filter unit onto the surface to be treated. � Check the height adjustment (approx. 6 mm) of the blast cleaning machine. Fig. 5.1 � For the height adjustment, an 6 mm sheet steel strip is shifted below the magnetic sealing. 3

Replace or repair all damaged parts before starting the machine. � Connect the blast cleaning machine and the filter unit with the dust hose. Use hose clamps at the connections. � Connect the supply cable of the filter unit with the site supply. � Connect the supply cable of the blast cleaning machine with the site supply. Make sure that the correct electric supply is available (230V, 50Hz, 16A for 230V plug). � Fill the separator (2) equally with the selected abrasive (see Chapter 3.9) up to the bottom of the separator tray. The magnetic valve must be closed whilst doing this. Fig. 5.2 Fill in abrasive here! � Check that the filter dust container has been emptied. Please comply with the local waste treatment regulations considering the removed material. 4

All persons in the proximity of the machine must wear safety glasses with lateral protection as well as safety shoes. The operator is obliged to wear close-fitting protective clothing. The start of the blast cleaning machine and the filter unit is effected in the following sequence: 1 Switching on the filter unit � Please see the Operating Instructions of the filter unit. 2 Initial operation of the blast cleaning machine � Pull out the plunger in order to unlock the valve lever. Fig. 5.3 5

5 Plunger 6 Limit switch � Pull the switch lever on the machine handle slowly to it’s stop. The blast wheel motor switches on. At the same time the magnetic valve is opened. � Slowly move the machine forward and observe the blast cleaned surface, and change the advancing speed if necessary. When the blast head is lifted from the floor, abrasive escapes from the sides of the blast head at high speed. If the machine is moved with the blast head raised, the abrasive magnetic valve must be closed. Alter the travel direction only after having closed the magnetic valve. The dust container of the filter unit must be emptied regularly. Comply with the local waste treatment regulations considering the removed material. 6

6.1 Daily operation 6.2 Information about advancing speed 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 6.8 Measures before and after long standstills 1

Normal start-up and operation of the blast machine 1-7D is no different from the procedure described in Chapter 5 "Initial operation". Carry out blasting in parallel tracks in such a way that the dust hose and electric cable do not become twisted. Figure 6.1 shows the recommended blast paths leading away from the filter 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 for a good blast result. In the case that the surface has different characteristics (e.g. different hardness or different coating thicknesses), a uniform blast result can be achieved by varying the advancing speed during blast cleaning. 6.2 Information about advancing speed The advancing speed depends on the material of the surface to be blast cleaned and the desired profiling. The correct advancing speed can be found out by observing the blasted surface and varying the speed during the blast cleaning process. Slight profiling on concrete requires a higher speed than coarse profiling. Blasting on steel requires a very low advancing speed. 2

Position the filter unit near to a power supply connection. Place the blast cleaning machine near to the filter unit and spread out 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 hose 3 Blast cleaning machine Travel stepwise over the work area considering the service length of the dust hose. Finish the blast cleaning process by blasting the area where the filter unit originally stood. 3

� Release the dead man’s handle for so that it snaps back into its resting position. The magnetic valve is closed and the blast motor will stop turning after approx. 10 seconds. � Advance the machine until you are sure that no deep holes are being blasted into the surface. Make sure that all turning machine parts have come to standstill before any inspection or maintenance works are started. � To avoid unintended switching on of the machine, lock the valve lever with the plunger! Fig. 6.2 When the ISPC Blastrac/EBE blast cleaning machine is put out of operation for a longer period of time, pull out the mains plug and cover the machine with a plastic foil. 6.5 What to do if a fault occurs Irrespective of the following information, the local safety regulations are valid in any case for the operation of the machine. First put the machine to its Safety off position. After that start looking for the defect. 4

The machine must be put to its safety off position before starting repair works. See Chapter 2 “Safety instructions”. 6.7 Restarting after a fault See Chapter 5 “Initial operation“. All persons in the proximity of the machine when in operation, must wear safety glasses with lateral protection as well as safety shoes. The operator is obliged to wear close-fitting protective clothing. 6.8 Measures before and after long standstills Standstill of the machine for a maximum of 3 months. Before 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 parts of the machine and power pack with Tectyl 506, for example, or a similar preservative. After a long standstill period See Chapter 5 “Initial operation”. 5

7.1 Recommendations 7.2 Maintenance and inspection list 7.3 Repairing 7.4 The blast pattern 7.5 Setting the magnetic and brush seals 7.6 Changing the tune-up kit 7.7 Changing the liners 1

secure the machine against unintentional switching-on. Put the machine to its safety off position. Failures due to inadequate or incorrect maintenance may generate very high repair costs and long standstill periods of the machine. Regular maintenance is therefore imperative. Operational safety and service life of the machine depend, among other things, on proper maintenance. The following table shows recommendations about time, inspection and maintenance for the normal use of the machine. The time indications are based on uninterrupted 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 year. Due to different working conditions it cannot be foreseen how frequently inspections for wear checkings, inspection, maintenance and repair works ought to be carried out. Prepare a suitable inspection schedule considering your own working conditions. Our specialists will be happy to assist you with more advice. The subsupplier’s operating and maintenance instructions should also be followed during service and maintenance. This applies especially to the instructions for electric components. 2

Operating hours/ time period Inspection points, maintenance instructions 12 h after repairing Check the efficiency of all safety devices. Check all accessible screw connections for tight seat. every 3 h Check whether there is any foreign matter in the hopper, the feed spout or in the blast wheel unit. Check the level of abrasive in the storage hopper. Top up if necessary. daily and prior to starting work Check the hose connections for tightness and fixed seat. Check the hose to the filter for damages. Make sure that the dust container of the filter is emptied. Check blast wheel, feed spout, liners and fasteners for wear and damage. Check the separator parts for wear and defects. Remove foreign bodies and dust deposits. Check the level of abrasive in the storage hopper. Top up if necessary. Check the magnetic, rubber and brush seals for wear. Check the electric connections for sediments of dirt or foreign bodies. Check the electric motor for dirt and other contaminants. annually Full overhaul and cleaning of the complete machine. 3

to execute the first repair works on the machine with the help of ISPC Blastrac/EBE personnel. With this your maintenance personnel gets the opportunity to be trained intensely. Only those repair works are described which occur within the context of maintenance or which are 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 cannot be supplied quickly. As a rule, production standstill periods are more expensive than the cost for the corresponding spare part. Screws that have been removed must be replaced with those of the same quality (strength, material) and design. Prior to any repair works on the machine and its drives, secure the machine against unintentional switching-on. Pull out the mains plug in order to do this. 4

Abrasive leaving the blast wheel blades is not thrown in all directions. Scatter is restricted to an angle of about 50°. This is achieved through the use of a control cage which surrounds the impeller. The position of the window in the control cage determines the blast pattern. 5 2 3 4 1 Fig. 7.1 1 Feed spout 2 Control cage 3 Positioning pin 4 Cage clamp 5 Cage retaining plate with positioning hole The position of the control cage has been set by ISPC Blastrac/EBE and is fixed by pins and recesses. Do not remove any fixings. Incorrect adjustment of the control cage results in very high wear and premature blasting-through of the liners in the blast wheel housing, as well as reduced blasting performance and a possible loss of the rebounce energy of the abrasive. Every time the control cage is replaced, the thread of the blast wheel fastening nut should be checked. Make sure that this nut will be tightened correctly. In addition, absolute care must be taken to clean the thread from dust and abrasive. 5

retaining plate is positioned correctly on the positioning pin of the blast housing. Do not remove any fixings. 1 2 Fig. 7.2 1 Cage retaining plate with positioning hole 2 Positioning pin 7.5 Setting the magnetic and brush seals The adjustment height of the magnetic seals, parallel to the surface to treated, should be set to about 6 mm everywhere. Fig. 7.3 For the height adjustment an 6 mm (stainless) steel strip is shifted below the magnetic sealing. 6

quantity: 1 Rear setting screw (2) quantity: 2 Adjust the height with the setting screws until the correct distance of 6 mm has been reached. With the ISPC Blastrac/EBE model 1-7D the adjustment is done using 3 setting screws (one each at the rear wheels and one at the front drive wheel bracket). The height of the brush seals should be maximum 1 mm above the surface. Adjustment is effected through slotted holes. 7

The tune-up kit consists of the blast wheel and the control cage. Demounting: 1 2 3 4 5 6 7 Fig. 7.5 1 Remove the feed spout (1) by pulling the feed spout out of the housing. 2 Loosen the cage clamps (2) and remove the control cage (3). 3 Unscrew the 4 screws of the cage retaining plate (4) and take it off. 4 Loosen the fixing nut (5) of the blast wheel (6) while holding the blast wheel still. Take the blast wheel out of the housing. 5 Check the wheel hub (7) for wear and replace it if necessary. 8

the blast wheel (2) on the wheel hub (1) through the blast housing opening. Tighten the blast wheel by fastening the fixing nut (3). 2 Fix the cage retaining plate (4) using the appropriate nuts and washers. 3 Insert the control cage (5) in the centre and clamp the control cage with the cage clamps (6) so that the blast wheel can rotate freely. Turn the blast wheel manually. It must rotate freely. 4 Place the feed spout (7) on the control cage. 9

The liners can only be changed when the tune-up kit is removed. Demounting: Fig. 7.7 1 Loosen the pressure screw (3) of the top liner. 2 Loosen the fastening screws (1+2) for the left and right liners, turn the liners towards the inside of the blast housing and take them out at the bottom of the housing. 3 If present, loosen the fastening screws (4) of the top liner. 4 Take the top liner out at the bottom of the housing. 10

and clean them if necessary. 2 Place the top liner (1) inside the housing. 3 Place the side liners (3+4) inside the housing, in a way that the liner sticks out approx. 2 mm at the bottom of the housing. Fasten the side liners with nuts (5+6). 4 Mount the top liner pressure screw (9). Make sure that the top liner sits close at the edges of the side liners. Tighten the pressure screw (7) of the top liner slightly and press the top liner against the side liners. Lock the screw with a nut. 11

8.1 Recommendations for the electrical systems 8.2 Circuit diagram 1-7D 1

Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by trained persons under the guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations. Order electric components referring to the circuit diagrams in Chapter 8.2 or contact ISPC Blastrac/EBE Customer Service. Observe the regulations of EN60204-1 and VDE0701 (measurements after maintenance and repairs). 2

Prior to any repair works on the machine or its drives the machine must be secured against unintentional switching-on. Put the machine to its Safety off position. Fault Possible cause Remedy Excessive vibration Blast wheel is worn irregularly. Imbalance due to worn or broken wheel blades. Replace the tune-up kit and remove all broken parts from the machine. Unusual noise Too little play or poor alignment of the rotating parts. Loose and incorrect set screws. Squeaking wheels. Seizing motor. Check alignment of the rotating parts (blast wheel and control cage). Check whether all screws and parts are fixed tightly). Replace the wheels. Replace the motor. Reduced or no blasting performance Inadequate abrasive supply to the blast wheel. Feeding of abrasive - magnetic valve and abrasive storage hopper. Blast wheel or control cage. Adjustment of the magnetic valve. Clean wire mesh, top up abrasive if necessary. Check and clean blocked feed spout or magnetic valve. Worn blast wheel or control cage, replace tune-up kit if necessary. Check the adjustment of the magnetic valve. 2

At the start of the blast process too much abrasive at once hits the wheel. The advancing speed is too high. Close the magnetic valve and stop the blast wheel motor. Start the blast process again and slowly open the valve. Reduce the advancing speed. Abrasive loss on the surface or escaping abrasive at the blast head Incorrect height adjustment of the magnetic seals. Worn magnetic seals. Poor abrasive quality. Worn tune-up kit. Adjust the magnetic seals. Replace the magnetic seals. Contact ISPC Blastrac/EBE. Replace the tune-up kit. Contaminated abrasive The filter unit is not generating enough suction power so that dust remains in the abrasive. Check the filter unit (cartridges and seals) Excessive wear in blast housing and rebound plenum Wrong abrasive. Incorrect setting of the control cage Contact ISPC Blastrac/EBE. Make sure that the cage retaining plate is positioned correctly. 3

Blast wheel unit Item Part no. Description Qty. 1 001628 Tune-up kit 1 2 959635 Wheel hub 1 001626 Cage retaining plate 1 3 959639 Wheel nut 1 970012 Control cage clamp 2 4 969580 Left liner 1 5 969581 Right liner 1 6 959676 Top liner 1 B21044 Top liner (casted) 1 2 1 3 4 5 6 Fig. 10.1 2

2 2 001624 Side brush 2 3 969763 Front magnet 1 4 969780 Side magnet 2 Fig. 10.2 Drive unit Item Part no. Description Qty. 1 971518 Swivel castor 2 2 960682 Wheel 2 3 001627 Wheel support 1 4 B20052 Front wheel bar 1 Fig. 10.3 3

1 2 969586 Liner fixing screw 2 3 B20066 Control lever 1 4 B20069 Steering handle 1 5 001601 Steering handle bracket 1 6 001170 Clamp handle 2 7 B20321 Rubber seal 1 960855-1 Felt seal 1 Fig. 10.4 4 3 2 7 1 5 6 4

1 6 972161 Hopper seal 1 6 4 1 3 2 5 Fig. 10.5 5

Item Part no. Description Qty. 1 969819 Magnetic valve (complete) 1 2 971500 Feed spout seal ring 1 3 001605 Valve lever 1 4 967577 Feed spout 1 5 Motor switch plate 1 6 001171 Plunger 1 7 B20091 Spring 1 1 3 6 2 4 7 5 Fig. 10.6 6

Item Part no. Description Qty. 1 B20204 Abrasive control cable 1 2 491726 Nipple and nut 1 Fig. 10.7 Blast wheel drive Item Part no. Description Qty. B21649 Blast wheel motor (complete) 1 1 B21651 Blast motor cover 1 2 B21652 Blast wheel motor 1 3 B21650 Blast motor mount plate 1 Fig. 10.8 7

Operating Instructions 1-7D Spare parts Electrical parts Item Part no. Description Qty. 1 001630 Limit switch 1 2 004571 Electric cable 1 001205 Plug 230V 1 3 Connection box 1 Fig. 10.9 8

1 Maintenance box complete 001631 1 Metal box 001030 1 Left liner 969580 1 Right liner 969581 1 Top liner 959676 1 Tune-up kit 6“ 001628 1 Abrasive control cable B20204 2 Side brush 001624 2 Front & rear brush 001623 1 Open end spanner 10/11 001017 1 Open end spanner 13/17 001040 1 Open end spanner 17/19 001019 1 Open end spanner 24/26 001042 1 Box spanner SW 17 mm 001043 1 Screwdriver 5,5 x 100 001032 1 Ratchet spanner 3/8" 001010 1 Ratchet spanner extension piece 001025 1 Combination pliers 001034 1 Hammer 001000 1 Safety glasses 001031 1 Box spanner 26 mm 000112 1 Handle 000111 9