BNVS605_OM

BNVS605_OM
BLAST N' V AC®
SYSTEM
BNVS-600 I BNVS-605
OPERATING
INSTRUCTIONS
EMPIRE ABRASIVE EQUIPMENT CO. 2101 W. CABOT BLVD. LANGHORNE PA 19047
(215) 752-8800
FAX (215) 752-9373
WWW.empire-airb last. com
TABLE OF CONTENTS
SET-UP PROCEDURE ........................................................................................................ .
1.0
2.0
2.1
2.2
2.3
2.4
2.5
OPERATING PROCEDURE...............................................................................................
START-UP..............................................................................................................................
ROUTINE INTERMITTENT SHUTDOWN..........................................................................
SHUTDOWN FOR RELOADING ABRASIVE.....................................................................
FINAL SHUTDOWN..............................................................................................................
MISCELLANEOUS .... ........ ... ... .. ... .. .. .. .. .. ... .. .. .. ..... ..... .... .. ... ... ..... ..... .. .. .. ... .. .. ..... ... .. ... .... .. ......
2
2
2
3
3
3
3.1
3.2
3.3
3.4
3.5
MAINTENANCE...................................................................................................................
DAILY MAINTENANCE.......................................................................................................
WEEKLY MAINTENANCE..................................................................................................
MONTHLY MAINTENANCE OR 200 HOURS OF OPERATION......................................
REPLACING THE DIAPHRAGM.........................................................................................
CHECKING OR REPLACING THE METERING TUBE.....................................................
4
4
5
5
5
5
TROUBLESHOOTING........................................................................................................
PROBLEM-POOR PRODUCTION........................................................................................
PROBLEM-PULSATING OR SURGING GRIT FROM NOZZLE.......................................
PROBLEM-NO FLOW OF COMPRESSED AIR OR GRIT..................................................
PROBLEM-FLOW OF AIR THROUGH THE NOZZLE, BUT LITTLE OR NO FLOW
OF GRIT..............................................................................................................
PROBLEM-UNABLE TO STOP THE FLOW OF COMPRESSED AIR..............................
PROBLEM-GRIT SURGING FROM NOZZLE WHEN POT IS PRESSURIZED AND
CONTROL HANDLE NOT DEPRESSED.........................................................
PROBLEM-PREMATURE WEAR OF TEE UNDER SURE-FLO GRIT VALVE...............
PROBLEM-WHEN OPERATOR'S HANDLE IS FIRST DEPRESSED GRIT AND AIR ARE
NORMAL, BUT AFTER START TIME, GRIT FLOW GRADUALLY STOPS,
LEAVING ONLY AIR FLOW............................................................................
6
6
6
6
3.0
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
7
8
8
9
9
REFERENCE DIAGRAMS & FIGURES
DIAl
DJA 2
FIG 1
FIG 2
FIG
FIG
FIG
FIG
FIG
FIG
FIG
FIG
FIG
FIG
FIG
FIG
".)
4
5
6
7
8
9
10
11
12
13
14
BNVS-600 SYSTEM CONFIGURATION DIAGRAM.........................................................
BNVS-605 SYSTEM CONFIGURATION DIAGRAM........................................................
SUPERBLAST WITH MANUAL CONTROLS.....................................................................
SUPERBLAST WITH SAF-STOP II, 780 SERIES PNEUMATIC REMOTE
CONTROLS INSTALLED..................................................................................
SYSTEM VALVE REFERENCE GUIDE..............................................................................
AUTOMATIC HIGH PERFORMANCE SURE-FLO (INTERNAL PARTS)........................
AUTOMATIC SURE-FLO (SPRING AND DIAPHRAGM ASSEMBLY)...........................
AIR FLOW IN BLAST POT ILLUSTRATION.....................................................................
BNV -3 WORKHEAD COMPONENTS..................................................................................
BNV-3 BRUSH SET USE GUIDE........................................................................................
SUPER-FIVE WORKHEAD COMPONENTS.......................................................................
BNV-4/ BNV-6 WORKHEAD COMPONENTS....................................................................
BNV-4/ BNV-6 WORKHEAD PARTS BREAKDOWN........................................................
PRESSURE REGULATOR PARTS BREAKDOWN.............................................................
AQUAMATIC DIAPHRAGM VALVE PARTS BREAKDOWN..........................................
VACUTRANS PARTS BREAKDOWN..................................................................................
10
11
12
12
13
14
14
15
16
17
18
19
20
21
22
23
In addition to the Blast N' Vac® System, you will need two items to begin operation ... the blasting abrasive of
your choice and a compressed air supply with a minimum 114" ID air supply line. To operate the system at
conventional 100 psi blast pressures, you will need to provide a minimum of 600 cfm of compressed air.
1.0
SET-UP PROCEDURE (reference figures 1, 2 & 3)
a.
Unpack and lay out for identification all loose parts. System containers are often used as packing, so
be sure to check inside each for loose parts.
b.
Pneumatic remote controls with dual lines (fig 2, item 24) are supplied with system. Fittings on one
end are already connected to remote control switch. Connect the other ends to the proper fittings on
the system's control panel.
c.
Connect the blast line to the fitting (fig 1, item 8) on the bottom of the blast machine. Be sure to
secure with a safety wire.
d.
Connect the short 3" vacuum hose from the recovery container to the back of the control panel, then
the 50' x 3" vacuum hose from the front side of the control panel to the workhead.
e.
Install an air coupling (not supplied) to the compressed air inlet point for the system (1 14" pipe
nipple). Do not use a coupling that restricts air flow.
f.
Connect the air line from the compressor to the air coupling just installed on the system. Keep length
as short as possible. For optimum blasting productivity, use an air line at least three times the I. D. of
the nozzle orifice. 114" T.D. or larger hose is generally used.
g.
Hook-up the 2" and 3" vacuum lines to container lids as in system configuration diagram 1 or 2.
These are color coded for your convenience.
h.
Close Vacutrans® air supply valve (Fig 3, item 29).
1.
Close Blast Pot air supply valve (Fig 3, item 17).
j.
Close exhaust valve (Fig 3, item 18).
k.
Open choke valve (Fig 3, item 4).
l.
Close Sure-Flo grit valve on bottom of blast pot (Fig 3, item 28) by rotating "T" handle clockwise.
Open pressure regulator (Fig 3, item 30) by turning fully clockwise.
m.
Fill water bath container to 113 level (bottom of standpipe should be submerged in the water).
n.
Re-set lid on water bath and be sure lids on both it and the material recovery container are sitting
securely on gasket material and that moisture barrier inside drum is positioned properly on its
hanging brackets.
o.
Lay out vacuum and blast hoses WITH ATTENTION TO MINIMIZING BENDS.
p.
Thread blast nozzle into holder on end of blast hose.
q.
Thread workhead onto same holder on end of the blast hose. Thread until snug then back off one full
turn. This allows the workhead to swivel, minimizing operator fatigue.
r.
Clamp 3" vacuum hose onto vacuum port ofworkhead.
1
s.
Be sure workhead center tube (attached over end of blast nozzle in BNV-3 tool and set into tool body
on BNV-6) and brushes (one in BNV-6 and two in all otherworkheads) are installed. NEVER USE
BNV-3, SUPER-FIVE, BNV-5 OR RIGHT ANGLE WORKHEADS WITHOUT THE DOUBLE
BRUSH ARRANGEMENT.
t.
Fill the blast pot with Q!:y grit through the large 6" opening in the top. Do not overfill. BNV system
grit capacity is 6.5 cubic feet.
u.
Make sure the operator is equipped with recommended protective equipment including EYE and
HEARING PROTECTION. NIOSH requires the use of an air-fed hood, remote controls, canvas
jacket, pants and leather gloves. It is recommended that the air-fed hood be equipped with an air
purifier, free air pump and/or CO (carbon monoxide) monitor.
YOU ARE NOW READY TO BEGIN OPERATION
2.0
OPERATING PROCEDURES (reference fig 3)
2.1
START-UP
a.
Turn on compressor.
b.
Open Vacutrans® air supply valve (fig 3, item 29). Always open this valve before the blast pot air
supply valve (fig 3, item 17).
c.
Open blast pot air supply valve (fig 3, item 17). Be sure exhaust valve (fig 3, item 18) is closed.
Blast pot will pressurize.
d.
Depending on the combination of the coating being removed (if any), the composition of the substrate
and the type of abrasive, the pressure of the blast stream may need to be adjusted to suit the needs of
the particular job. Removing an epoxy coating from steel and achieving a white metal blast spec with
sand would require at least 100 psi, whereas using plastic blast media to remove the same coating
from a thin aluminum surface may only need 40 psi. Pressure regulator (fig 3, item 30) should be set
full open (clockwise rotation of"T" handle) as described in set-up procedure (section 1.0). This will
allow blasting at the full pressure the compressor can supply. To blast at lower pressures, turn "T"
handle counter-clockwise while bleeding air out the exhaust valve (fig 3, item 18) or the petcock on
the bottom of the moisture trap. The regulator on the Blast N'Vac® system is a non-relieving type.
Clockwise turning of the adjusting screw will increase presssure. Reverse rotation of the adjusting
screw will not reduce pressure unless the pressure is "bled off'.
Grab Blast N'Vac® workhead and put in contact with surface to be blasted. Close remote control
switch and blasting will begin. Initially no abrasive will come from blast nozzle since the grit valve
(fig 3, item 28) was closed in the set-up procedure (section 1.0). Have a second person adjust this
valve out (counter-clockwise rotation of"T" handle) until abrasive flow is visibly doing the proper
amount of work. From the point of first noticing abrasive flow, it will take only 5-6- full turns of "T"
handle to fully open valve. Past that point, the handle will still turn but will have no effect on
abrasive flow.
e.
f.
Remote control switch must be constantly depressed to continue blasting.
g.
Brushes on end ofworkhead must be kept in constant contact with surface to achieve full vacuum
recovery and control of abrasive and dust.
2
2.2
ROUTINE INTERMITTENT SHUTDOWN- Simply release remote control switch and blasting will
stop. Vacuum runs constantly, remote switch controls blasting only. Depending on hose lengths
there is a slight delay in actual start-up and shutdown of abrasive flow when actuating the switch.
Keep head in contact with surface while delay is taking place.
2.3
SHUTDOWN FOR RELOADING ABRASIVE
a.
Release remote control switch.
b.
Close blast pot air supply valve (fig 3, item 17).
c.
Close Vacutrans® air supply valve (fig 3, item 29).
d.
Open blast pot exhaust valve (fig 3, item 18).
e.
Fill blast pot manually if using "600" system or through hopper dump valve if using "605" system.
Empty or replace recovery drum in "600" type system.
f.
blast
Open Vacutrans® air supply valve (fig 3, item 29), close exhaust valve (fig 3, item 18) and open
pot air supply valve (fig 3, item 17). You are now ready to begin blasting again.
g.
2.4
During this shutdown is a good time to check brushes and center tube in workhead for wear and
replacement. Replace brushes when excessive abrasive loss or wear is noted. Check center tube for
wear each time brushes are replaced and change it when end begins to flare. Also periodically check
water level in water bath dust filter as water loss will occur over time.
FINAL SHUTDOWN- If possible, schedule final shutdown to coincide with the blast pot being empty
of abrasive.
a.
Proceed as in 2.3 a, b, c and d (SHUTDOWN FOR RE-LOADING ABRASIVES).
b.
Close air supply valve on compressor and shut down according to manufacturer's instructions.
c.
Bleed off air in supply line from compressor to system by opening exhaust valve (fig 3, item 18) until
pressure is released, then close again.
d.
System is now completely de-pressurized.
2.5
MISCELLANEOUS
a.
The center tubes in all Blast N'Vac® workheads are high wear items. On the BNV-2.5 & BNV-3
workheads, the center tube slides over the end of the blast nozzle. In the Super-Five & BNV-6, the
center tube slides into the body of the workhead and is secured with set screws. These center tubes
should be checked on an hourly basis and replaced when they show excessive wear. PROLONGED
BLASTING WITH A DETERIORATED CENTER TUBE WILL DESTROY CRITICAL PARTS OF
THE WORKHEAD.
b.
The BNV-6 workhead utilizes a single brush. All other workheads use a two brush setup. As the
interior brush nears destruction, be sure to replace it before destroying the outer brush. Brushes
should generally be replaced when abrasive loss at the blast point is noticed. DOUBLE BRUSH
WORKHEADS MUST ALWAYS HAVE BOTH BRUSHES IN PLACE TO AVOID PREMATURE
WORKHEAD DAMAGE.
3
c.
for optimum operation and abrasive recovery, try to keep the workhead unit as perpendicular to the
work surface as possible. With a little practice, your technique and efficiency will improve by the
hour. ON BNV-3 AVOID PUTTING TOO MUCH FORWARD PRESSURE ON BRUSHES
CAUSING THEM TO BEND INTO BLAST AREA AS YOU MOVE.
d.
When moving the system from place to place, be sure all components are secure. RECOVERY
HOPPER SHOULD NOT BE ON TOP OF BLAST POT WHEN MOVING RECYCLING MODELS.
e.
Abrasive blasting can produce harmful levels of respirable dust. Accident or improper handling of
this equipment can create such dust. Breathing protection is recommended. EYE and EAR
PROTECTION is strongly recommended during operation.
r:£F
CAUTION
~
When changing workheads on BNV systems, be certain to remember to change to proper center tube. The
BNV-3 workhead (no wheels) uses only the specially sized No.4 nozzle and the center tube slides directly onto
the end of the nozzle. The Super-Five & BNV-6 workhead (with wheels) can use the same nozzle but the
center tube MUST be removed as the center tube for the Super-Five or BNV-6 workhead slides into the body of
the tool and is held in place with set screws. The BNV-5 and Right Angle workheads use no center tubes.
Never turn off air compressor before de-pressurizing the Blast N'Vac® system.
Condensation can occur overnight. Therefore, empty the blast pot of grit at the end of each day. The most
efficient method to empty the blast pot is through normal blasting. However, if you want to empty the blast pot
quickly, the following should be done:
First, remove the blast nozzle. Close the choke valve (fig 3, item 4) and open the Sure-Flo grit valve (fig 3,
item 28). Close the exhaust valve (fig 3, item 18) and open the blast pot air supply valve (fig 3, item 17).
Close remote control switch. Grit will be forced out of the blast pot in a dense phase through the blast hose.
The pressure regulator can be used to control the velocity of the abrasive stream. When all abrasive is cleared
from the blast pot, follow normal shutdown procedure.
Cover blast pot if stored outside to prevent rain from entering pressure vessel.
3.0
MAINTENANCE (reference figs 1-5)
3.1
DAILY MAINTENANCE (reference figs 1 & 2)
a.
All rubber washers on nozzle, blasting hose and air line couplings must be properly installed and in
good condition.
b.
Check operator's protective equipment, such as blasting hoods, gloves and protective clothing.
c.
All couplings must be equipped with safety wires.
d.
The nozzle (fig 1, item 16) must be tightly secured to nozzle coupling (fig 1, item 15). Do not use the
nozzle without a washer. This will cause premature wear to nozzle and coupling.
e.
Open the drain valve on the moisture & oil separator (fig 1, item 11) to remove any accumulation of
moisture. Allow unit to bleed a small amount of air during damp conditions!
f.
Dual line hose (fig 2, item 24) must be in good operating condition and tightly secured at the
operator's control handle and at the blast pot.
4
g.
3.2
Purge moisture filter of accumulated matter by depressing drain valve located on bottom of filter
bowl. (Filter located on inlet air piping, left side of control panel.) Replace cmiridge filter if clogged
with debris. Unscrew clear bowl off filter base, then unscrew filter retainer and filter element.
Replace with filter element RP-646.
WEEKLY MAINTENANCE (reference fig I)
a.
Check the nozzle for wear. A nozzle is considered worn when it wears to half again its original size.
A drill bit can be used to measure the nozzle opening. Blasting with a worn nozzle may reduce
operating pressure which will reduce blasting speed.
b.
The specially constructed blasting hose should be checked for signs of wear. Replace if any soft spots
are found.
c.
Inspect the sealing "0" ring (fig 1, item 1) and sealing plunger (fig I, item 2) for signs of wear.
Replace if worn.
d.
Check all valves for good operating condition.
3.3
MONTHLY MAINTENANCE OR 200 HOURS OF OPERATION (reference figs 3 & 4)
a.
Check metering tube (fig 4, item 2B) in the Sure-Flo grit valve (Fig 3, item 28) for wear or ruptures.
In the automatic Sure-Flo grit valve, the tube may be worn if the nozzle does not shut off when the
remote control handle is released. Replace if defective.
b.
Check rubber diaphragm (fig 4, item 14B) in the automatic Sure-Flo grit valve to see that it is in good
operating condition. Air leaking through or around a diaphragm will escape through the vent hole in
the diaphragm cover indicating need for replacement.
3.4
REPLACING THE DIAPHRAGM (reference figs 4 & 5)
Loosen jam nut (fig 4, item I IB) and back spring tensioner (fig 4, item 12B) with handle (fig 4, item
98) approximately 1Yz" from Sure-Flo spring enclosure (fig 4, item 138). It is not necessary to
totally remove tensioner. Remove the six bolts holding the spring enclosure (fig 4, item 13B) to
diaphragm cover (fig 4, item 15B). Unscrew plunger (fig 5, item 3C), remove steel washer (Fig 5,
item 4C) and the spring and diaphragm assembly (fig 5, item 7C). After replacing old diaphragm
with a new one, re-install steel washer (fig 5, item 4C), rubber washer (fig 5, item 5C) and plunger
(fig 5, item 3C). Be sure washers are centered on spring retaining nut prior to tightening.
Reassemble spring enclosure in reverse order.
IMPORTANT: NEVER DISASSEMBLE SPRING ASSEMBLY. The spring assembly is under
compression. Removing components could cause injury. Replacement requires purchase of a
complete assembly (PIN 290296).
3.5
CHECKING OR REPLACING METERING TUBE (reference fig 4)
Pot should be empty. Shut off main air valve and de-pressurize blast pot. Disconnect blast hose from
tank coupling. Disconnect flexible choke line hose assembly from Sure-Flo (fig 1, item 6).
Disconnect W' air control hose from adapter (fig 4, item 188) on Sure-Flo diaphragm cover (fig 4,
item l5B). Back jam nut (fig 4, item 118) spring tensioner (fig 4, item 12B) and handle assembly
(fig 4, Item 98) out from spring enclosure (fig 4, item 13B) approximately 1Yz". It is not necessary to
remove completely from the Sure-Flo. Remove four carriage bolts holding lower flange (fig 4, item
178) to body (fig 4, item 48). Remove lower flange back bolt (fig 4, item 38) to relieve pressure on
the metering tube (fig 4, item 2B). Remove old tube and install new metering tube. Reassemble
5
bottom of Sure-Flo to top flange using four carriage bolts. Thread jam nut, spring tensioner and
handle assembly back into Sure-Flo spring enclosure. Completely tighten bolt (fig 4, item 3B).
WARNING: SURE-FLO GRIT VALVE SHOULD NOT BE DISASSEMBLED WHILE THE
BLAST POT IS UNDER PRESSURE !
4.0
TROUBLESHOOTING (reference figs 1-5)
4. I
PROBLEM- POOR PRODUCTION
a.
Air pressure is an extremely important factor. In most cases poor production can be traced to lack of
air. This is generally caused by the following:
1) The compressor is too small for the nozzle being used.
2) The !.D. size of the air line is too small. Generally 1'/4" I.D. or larger air hose should always be
used.
3) Restriction of air caused by improper fittings. As a general rule, the blasting pressure at the
nozzle should be approximately 100 psi.
b.
Grit size too small. A general rule to remember: The thicker the material being removed, the coarser
or larger the grit particle should be.
c.
Blast finishing a part which is oily or wet- the surface must be absolutely dry and free of any oil,
grease, water, etc.
d.
Operating with an improper setting at the grit valve- if the mixture is either too rich or too lean, it
will affect the operator's performance.
4.2
a.
PROBLEM- PULSATING OR SURGING OF GRIT FROM THE NOZZLE (reference fig 3)
Note: When blasting first starts, there will be an initial surge of grit from the nozzle. This is caused
by grit accumulated in the blast hose. After a few seconds, normal blasting should resume. If not,
check the following:
Operating with the choke valve (fig 3, item 4) partially closed. This valve must remain open during
blasting operations. The choke valve is designed to help in removing most obstructions found in the
pressure vessel and grit valve. By closing the choke valve, all the compressed air is forced into the
pressure vessel helping to push the obstruction down into the tee at the bottom of the Sure-Flo.
Opening the choke valve permits air to flow through the line, pick up the debris or obstruction and
carry it out the blast hose to the nozzle.
b.
Operating with an improper setting at the grit valve. If the grit mixture is too rich it will pulsate.
Gradually reduce the flow of grit. Note: The Sure-Flo grit valve only requires '14 turn to affect the
flow of grit and will take approximately 5 full turns to go from fully closed to fully open.
c.
Operating with damp grit. Grit must be absolutely dry to flow evenly through the Sure-Flo and blast
hose. On humid days, or when using an older compressor, it may be required to operate with the
moisture separator drain cocked slightly opened. If conditions persist, an air-drying system may need
to be employed in line between the compressed air source and the Blast N'Vac® system.
6
4.3
PROBLEM- NO FLOW OF COMPRESSED AIR OR GRIT (reference figs 1-3)
a.
Clogged nozzle - De-pressurize blast pot and remove the nozzle from the coupling and inspect for any
foreign material that may be lodged in the orifice opening. IMPORT ANT: DO NOT REMOVE
NOZZLE WHEN BLAST POT OR BLAST HOSE IS UNDER PRESSURE.
b.
CAUTION:
If nozzle is blocked, pressure may be present in the blast hose and may present
a hazard if the nozzle is removed. Blast pot should be depressurizcd.flrst, and the deadman
(remote control valve) actuated secondly, to open the abrasive control valve so the pressure will
be released from the blast hose into the blast pot. After the blast hose is depressurized, the
nozzle may be removed to clear away any obstructions.
c.
Clogged blasting hose. Remove the nozzle and washer from the coupling and while someone is
FIRMLY holding the blasting hose, do the following:
1) Close the Sure-Flo grit valve (fig 3, item 28).
2) Close the exhaust valve (fig 3, item 18).
3) Open the main valve (fig 3, item 17).
4) Depress the remote control handle.
This will force the compressed air through your blasting hose and dislodge packed grit. You may
have to disconnect the blasting hose and inspect the tank coupling for any foreign material.
d.
Remote Control Air Check- (reference figs 1 & 2)
1) Make sure 114" petcock (fig 1, item 12) is open.
2) Remove the plug in the Vi' pipe cross under the automatic air valve (fig 2, item 20). When
operator's handle is depressed, air should escape (a gauge screwed into this opening should show
minimum 60 psi supply). If no air escapes (or if pressure is less than 60 psi) check dual lines and
fittings for kinks or leaks. Trace control air through system as follows: Remove black line at
handle (fig 2, item 23) -air should escape. Re-connect black line and remove yellow line at
handle - air should escape when handle is depressed. By tracing air flow in this manner back
through the blast pot, location of the obstruction or leak can be determined.
3) If control air of adequate pressure is reaching automatic air valve (fig l, item 20), problem is
ruptured diaphragm in this valve. Note: A small volume of air bleeding from the stem of the
automatic air valve will be noticed when air control line is pressurized. This bleed is a safety
feature which shuts down the system if hoses should be accidentally crimped.
4.4
a.
PROBLEM- FLOW OF AIR THROUGH THE NOZZLE, BUT LITTLE OR NO FLOW OF GRIT
(reference figs 1, 3, 4 & 5)
Operating with an improper setting at the grit valve (fig 3, item 28). If the mixture is too lean, little
or no grit will be supplied to the nozzle.
b.
Clogged nozzle. Sometimes a clogged nozzle will allow air to pass, but little or no grit. Remove
nozzle (fig 1, item 16) from the coupling (fig 1, item 15) and inspect.
IMPORT ANT: DO NOT REMOVE NOZZLE WHEN BLAST POT IS UNDER PRESSURE !
c.
Blast pot is empty. Refill with grit.
d.
Contaminated grit - grit contaminated with moisture, excess fines, foreign material, large articles can
interrupt grit flow. This free flow is necessary for effective blasting.
7
e.
Clogged grit valve
1) Adjust the grit valve (fig 3, item 28) to full open position. While the machine is blasting, close
the choke valve (fig 3, item 4) for a few seconds; then open it fully. Doing this three or four times
should clear any temporary blockage. Reset the grit valve and continue blasting.
2) If step # 1 is not successful, de-pressurize the blast pot and back out the fixed bolt (fig 4, item liB)
and spring tensioner (fig 4, item 128) with tee handle at least 2/3". This will relieve all pressure
on the metering tube and allow it to open fully. Choke the blast pot as in step #I.
3) If step #2 is not successful, de-pressurize the blast pot. Remove the lower flange housing (fig 4,
item 178) from the regulator body. Inspect bottom opening of tank with flashlight. Also check
metering tube in Sure-Flo grit valve. Remove foreign material causing blockage. Reassemble
bottom half of Sure-Flo with metering tube to top flange. Continue blasting.
f.
Air leaks around Sure-Flo diaphragm assembly when blast pot is pressurized and blasting.
I) Tighten the six bolts around outside of spring enclosure (fig 4, item 138). If this fails to stop
leaks, proceed to next step.
2) Disassemble spring enclosure, check diaphragm (fig 4, item 148), tightness of plunger (fig 4, item
58 and fig 5, item 3C), and "0" ring (fig 4, item 68). Replace any worn part and re-tighten
plunger.
3) Plunger frozen in the closed position. Disassemble diaphragm body. Inspect plunger and plunger
guide (fig 4, item 58 and fig 4, item 168), replace if scored or frozen. Note: A new "0" ring (fig
5, item 2C) should be used and light film of white grease applied during re-assembly.
4.5
PROBLEM- UNABLE TO STOP THE FLOW OF COMPRESSED AIR (reference fig 1)
When hand pressure is removed from the remote control switch, the compressed air should stop
immediately. if the compressed air does not stop, the problem is in the automatic air valve or
operator's control.
a.
Check for a sticking plunger in the remote control switch. This can be done as follows: Remove
the yellow return line just behind the remote control switch. When the handle is depressed, air
should flow from the disconnected fitting. When the handle is released, the flow of air should
immediately stop. If flow does not stop, disassemble control handle and clean.
b.
Check that the plunger in the automatic air valve (fig 1, item 20) can move freely. After depressurizing the blast pot and shutting off the compressed air supply, remove the four bolts holding
on the automatic air valve cover plate. It should be possible to move the center stem up and down. If
stem does not move freely, disassemble and clean.
4.6
PROBLEM- GRIT SURGING FROM NOZZLE WHEN POT IS PRESSURIZED AND CONTROL
HANDLE NOT DEPRESSED (reference fig 4 & 5)
a.
Operating with spring tensioner (fig 4, item 128) and I or bolt( fig 4, item 38) not fully seated against
body. Turn in until fully seated as shown in fig. 4.
b.
Ruptured or worn metering tube (fig 4, item 28). Disassemble metering tube body. Inspect metering
tube and replace if defective.
c.
Plunger (fig 4, item 58) frozen in fully open or partially open position. Disassemble diaphragm body.
Note: A new "0" ring (fig 5, item 2C) should be used and a light film of white grease applied during
re-assembly.
8
4.7
a.
b.
4.8
PROBLEM- PREMA TlJRE WEAR OF TEE UNDER SURE-FLO GRIT VALVE
Operation with choke line valve partially closed. The choke line should always be fully open during
blasting.
Operating with worn metering tube in Sure-Flo allows air and grit to leak through tube even when not
blasting. Replace tube.
PROBLEM- WHEN OPERATOR'S HANDLE IS FIRST DEPRESSED, GRIT AND AIR ARE
NORMAL, BUT AFTER START TIME GRIT FLOW GRADUALLY STOPS
LEAVING ONLY AIR FLOW (reference fig 4)
a.
Leak through or around Sure-Flo diaphragm. If air escapes through vent hole in Sure-Flo housing
(fig 4, item I 5B) the Sure-Flo diaphragm is defective or its connecting hardware is not tightened
properly.
b.
Operator not holding remote control switch fully closed during operation.
13NVS600/6051NST 6/98
9
BNVS-600
DOUBLE VACUTRANS® SYSTEM
......
0
~
:
H
:
~ COALESCER
MUFFLERS -t
BNV-3
~
BLAST POT
RECOVERY DRUM
DIAGRAM 1
WATER BATH
1 1
BNVS-605
DOUBLE VACUTRANS® SYSTEM
RECOVERY HOPPER
BNV-6
WORKHEAD
/
......
......
.
~.
·"'
·:~ ,:[}/.~;~···;·
SUPER FIVE
~
~~~!;
BLAST HOSE
ASSEMBLY
BNV-3
~
\1
! !
._ COALESCER
MUFFLERS 1
~
BLAST POT
RECOVERY DRUM
DIAGRAM 2
WATER BATH
1 1
F,gure J
SUPERBLAST WITH MANUAL CONTROLS
1.
2.
3.
9a
4.
9e
6.
5:!:3872 Rullller '"0" t·ung-o··
625072 $6allng Plungor-Coated 8"
15602~ f>m_\u~ G&ug-V." NPT
617~ Air Valw (bfwl) with h&ndl&-1" NPT (Super131a.st-3!ia)
617-452 Air va,.,.(brJ3.1) with 1\andl_, ~· NPT
(Sup<IIBia.st-&.0 and larg...,
~ Raplaceable Handle (with right ang~ atop t&b) lor 1" VaJY11
505272 ~~· Handle .(with right angle atop tab) fci- 1%" Valve
&0713:2 Raplaceable Handle (With straight atop t&b) tor 1" V~
&071~ Rapi~~Ce&ble Handle (with atralght atop t.a.b) lor 1 \4" VaJY11
lnapee\lOf\ Door Aaaembly (wedge)
tnapeetlon Door A.asembly (clevta)
62-'1~
6.
0oor Gum
52Cin2 Flexible Hoae .Maembly SuperSI&St 350 (Prior to 51118-()
Flexlbl• Hoae A&Mmbly Supec1>1&at 350 (After tc 51118-()
Flexible Hoae A&Mmbly Supec1>1&at &50 (Prior tc 51118-()
Flexible Hose ,\t.aembly Supec1>1&at &50 (Aftef 511/8-()
Flexible Ho.. Aa&embly SuperSI&at 10!10 (Prior to 5/118-()
200333 Flexible Hose Aa&embly Supec1>t&at 1050 (After 511/M)
2903111
621022
29031;
1$21()(1:2
9
5-457~
1\4"X1\4" X T Tee
'
753:2e:2 Tank Coupling-Aluminum
'753:272 Tank CoupUng-Braaa
.
0. 2003Ir7 E..Z Fill Bag BINlw/Scn!ener, Complete
Ga. 852112 Bolt with Leek Washer and Nut
7.
8.
Slb. 76Zl72 Top l.bga
9c. '1629S2 Bottom l.bgs
lld. 762992 ~
llle. 551372 Screw
10. 1505062 Wheel-12" ~I Pneumatlc-(SuperSia.st-350)
1105072 Wheel-16" Semi Pneumatlc-(SuperSia.st-a50 and large~
11. 2901ln OF·1 Of)'·Fio Manual Drain Separat()(-1" NPT with bullt·ln
cl\eck (Not aupplled with Gauge or Drain Valve)
290192 01-Dry-FIO Manual Onlln Separator-1 \4" NPT With bullt·ln
check (Not aupplled with Gauge or Drain Valve.)
ISOO:ie2 ADS-1 AutOI!Ildlc Drain Separator-1" NPT (Nol aupplled with gauge)
I5().CU2 ADS-2 Automatic Draln Separator-1 y,• NPT (Not aupplled with
with gauge)
1.2. 518252 Onlln Valve-'A" NPT
13.
Blast Hose Coupling
14.
Blast Hose
15.
Nettle Coupling
16. ••
Nonie
17. Air VaiVI! (braM) with 1\andl&-1" NPT (SuperSiast-350)
517-452 Air Valve (btUS) with llandl-1 \4" NPT
(SuperStast-&.0 and Jarget)
504352 f\eptaoeable Handle (with right angle atop tab) for 1" Valve
505272 Replaceable Handle (with rtght angle atop tab) lor 1 V. • Valve
507132 Replaceable Handle (with atralght etop t&b) for 1" Valv-e
5071<12 Replaceable Handle (with atralght atop tall) lor 1v.• Valve
18. 5174-42 Air Valve (briM) with Handle
504352 Replec&able Handle tor 1" Va.lYe
Figure 2
SuperBiast with Saf-Stop II, 780 Series
Pneumatic Remote Controls Installed
****
YOUR BLAST MACHINE IS EQUIPPED
WITH THE 780 SERIES-GRIT VN..NE
AS DEPICI'ED IN THE DRAWING AT
THE RIGHT BO'I'ICM CORNER OF THIS
PAGE
****
Parts 1. through 19. same as Figure 1
20.
518052
'• 518062
21. 290371
290373
290375
22. 520642
23.
24.
1" Au.tomatlc Air Value (SuperBiast 350)
11/.;" Automatic Air Value (SuperBiast 650, 1050)
Control Hose (1n '') w/fittings installed (350)
Control Hose (W') w/flttings Installed (650)
Control Hose (1A'') w/flttlngs Installed (1050)
Shut-Off Valve
B- 5 56. Remote Control Switch
Dual Line (See Fig, 8 for parts)
·
521962 Dual Line Hose, 30' w/flttings Installed
521882 Dual Line Hose, 50' w/fittlngs Installed
521892 Dual Line Hose, 55' w/flttlngs Installed
16
12
FIGURE 3
SYSTEM V"ALVE REFERENCE GUIDE
----29
18
28
28
18
17
4
-
GRIT V"ALVE
EXHAUST V"ALVE (DEPRESSURIZATION)
BLAST POT AIR SUPPLY
CHOKE V"ALVE (FOR CLEARING POT OF ABRASIVE OR
OBSTRUCTIONS-NORMALLY OPEN)
29- VACUTRANS AIR.SUPPLY
30 - PRESSURE REGULATOR
13
58 168: 158
148
108
98
18
68
1B
28
38
48
58
68
78
88
98
753632
525802
552222
753692
505872
561422
290296
505812
753622
Figure 4
188
Pinch Roller
Metering Tube
Bolt
Valve Body
Plunger w/o Ring
"0" Ring
Spring Assembly
Handle Shaft
Handle
108
118
128
138
148
158
168
178
188
551732
552672
505832
753682
525012
753112
753462
753292
520222
N.Y. Loc Set Screw
W' Jam Nut
Spring Tensioner
Spring Enclosure
Diaphragm
Diaphragm Cover
Plunger Guide
Upper Flange
Hose Adapter
AUTOMATIC HIGH PERFORMANCE SURE·FLO [INTERNAL PARTS]
5C
2C
7C
\
1C
2C
3C
4C
5C
6C
7C
290296
561422
505872
552902
525002
525012
290306
Spring and Diaphragm As~:~embly
"0" Ring Repair Kit
Plunger
Washer
Dlaptiragm Gasket.
Diaphragm
Spring Assembly
Figure 5
I
---
I
'
AUTOMATIC SURE·FLO [SPRING AND QIAPHRAGM ASSEMBLY)
14
FIGURE 6
NON-BLASTING MODE
Air flow in a
pneumatic remote
controlled blaster in
both the blasting and
non-blasting modes.
Shaded areas are pN!ssur1zed
Shaded areas are pressurized
15
BNV-3 WORKHEAD COMPONENTS
FIGURE 7
I
B-023
CENTER WilE
---ll
I
I
B-104 BLAST NOZZLE
0\
REFER TO
A'ITACHED
SHEET FOR
BRUSH SETS
B-200 WORKHEAD BODY (INCLUDES BUSHING
&
B-201
~UZZLE
HOLDER
HANDLE)
B-040
BLAST NOZZLE
HOLDER BUSHING
B-025
HANDLE
CONSUMABLE PARTS FDR THIS WORKHEAD INCLUDE THE BRUSHES OUTLINF_.D ON THE FDLLCWING
SHEET AND THE B-023 CENTER TUBE. AN INNER BRUSH SHOULD LAST 2-3 HOURS OF BLAST TIME
AND THE CENTER TUBE SHOULD LAST 4-6 HOURS. OUTER BRUSH USAGE WILL BE AT A FRACTION
OF INNER BRUSH RATES DEPENDING ON OPERATOR.
BNV-3 BRUSH SET USE GUIDE
FIGURE 8
FOR USE ON
FLAT SURFACES
FOR USE ON
OUTSIDE 90°
CORNERS
FOR USE ON
INSIDE 90°
CORNERS
-
- -J
B-255
FLAT INNER BRUSH
B-250
B-2705
B-2605
FLAT OUTER BRUSH
OUTSIDE CORNER BRUSH SET
INSIDE CORNER BRUSH. SET
BNV-SUPER FIVE™ WORKHEAD COMPONENTS
PART OF
BLAST HOSE ASSEMBLY
FIGlJRE 9
~
BRUSHES
B-256 OUTER
B-257 INNER
B~105SV
If~
Iff!I
!I
,[ J/!
1
BLAST NOZZLE
0
·..
B~216
~
NOT
INCLUDEDl
B-201 NOZZLE HOLDER
~
WORKHEAD BODY (INCLUDES BUSHING & HANDLE)
{B~215 WORKHEAD BODY FOR BNV-5CT)
.......
00
£-1 CENTER TUBE
THUMB SCREW
·"-----~If
.
B~025
HANDLE
I
L
NOTE:
I
lj
II
7/-;' I
THE BNV-5CT WORKHEAD PARTS ARE INTERCHANGABLE BUT
INC! UDE THE USE OF A CENTER1UBE B-006A
B-040
BLAST NOZZLE
HOLDER BUSHING
--~------,
!
i
i
i
I
BNV-4 AND .BNV-6 WORKHEAD. COMPONENTS
FIGURE 10
I
B-006
.-------1
CENTER 'l!JBE
1~1
I
B-104 BLAST NOZZLE - 1/4"
(with BNV-4 workhead)
B-106 BLAST NOZZLE - 3/8"
(with BNV-6 workhead)
B-070
B-201
NOZZLE HOLDER
BRUSH HEAD
WHEEL KIT
,__.
B-011
1.0
0 ....._____,
0
...;;...
BELLCWS ASS I
y
B-040
NOZZLE
HOLDER
0
r-
BUSHThlG
B-080
I
LaVER
B-001
.BODY
ASS'Y
UPPER BODY ASS 1 Y
0
-
,.......
0
-
B-030
VACUUM 'PORT
WEAR SLEEVE
B-280
B-501
BRUSH
BRUSH SPACER
FIGURE 11
PARTS BREAKDOWN
PART NUMBER
DESCRlPTION
B-100
CCMPLETE BODY' ASSEMBLY' - INCLUDES ALL PARTS
ON DIAGRAM EXCEPT B-104 OR B-106 BLAST NOZZLE
B-001
UPPER BODY' ASSEMBLY - INCLUDES B-040 BUSHING
AND 3 THllMBSCREWS FOR HOLDING CENTER TUBE IN
PLACE AND B-030 VACUUM PORT WEAR SLEEVE
B-080
LCWER BODY' ASSEMBLY' INCLUDING GIMBLE RING
AND MISC HARCWARE Nor SHCWN ON DRAWING
B-Oll
BELLCWS ASSEMBLY INCLUDING 'IWO CLAMPS
B-006
CENTER TUBE
B-070
BRUSH HEAD WHEEL KIT - INCLUDES WHEEL M)UNT
BRACKETS, TENSION SPRINGS, ADJUSTING BOLT,
AXLES AND WHEELS
B-280
BRUSH
B-501
BRUSH SPACER
B-030
VACUUM PORT WEAR SLEEVE
B-040
PVC BUSHING - 2•• x
B-201
NOZZLE HOLDER
1~ 11
CONSUMABLE PARTS ON THIS WORI<HEAD INCLUDE THE B-280 BRUSH WHICH
SHOULD 2-3 HOURS OF BLAST TIME AND THE B-006 CENTER TUBE WHICH SHOULD
LAST ABOUT 4-6 HOURS OF BLAST TIME.
i
20
FIGURE 12
BR~AKDOWN
PRESSURE REGULATOR
Maximum Pressure 300 PSI-:-T~mp. Range 40° to 120°F
lnstallaUon
Before installing, blow out pipe line to remove scale
and other foreign matter. This unit has DAYSEAL.
pipe threads; use pipe compound or tape sparingly
to male threads only. Install regulator in pipe line so .
that air will flow from IN to OUT and as near as
possible to equipment being supplied. 'Connections
A and L are l'ormally for gauge use but may be
used for outlet purposes. To insure trouble·free
performance, a filter should be installed upstream of
the regulator.
Maintenance
If the air supply is kept clean, the regulator should
provide long periods of uninterrupted service.
Erratic regulator operation or loss of regulation is
most always due to dirt in the disc area. and
cleaning is in order.
Cleaning
Depressurize regulator. remove bottom plug, spring,
and disc. Clean parts with denatured alcohol, wipe off
seat and blow out body with compressed air.
Reassemble parts as a unit and screw into regulatorbefore tightening bottom plug make sure disc is in
center hole in body. Should regulator continue to
malfunction, obtain repair kit and replace parts
indicated below.
·
·
Adjustment
Clockwise turning of the adjusting screw increases
the reduced or regulated pressure. With relievingtype regulators the reduced pressure follows
adjustment of the screw, with non-relieving
regulators adjustment for lower reduced pressure
will not be obtained until the reduced pressure
system is "bled'off" or until air flow starts.
a
-,_
REPLACEMENT PARTS
Order by Repair Kit Number
. .
e;
--_}
e;
~
~
~ ~ z; ~
~
KrT NAME
KIT NO.
TEE IWIOLE Tl< 16Y
REP I.ACEMENi TK119A
KlT
.
R.Kl19B
REPAIR
KlT
R.Kll9Y
RELIEVING
RK119B
REPAIR
KIT
NONRELIEVING
1/4" & 3/8"
1/2"
3/4" thru
3/4"
1~" & 1~"
1/4"
RKllBA*
tun t8o
l/2"
3/4" & 1"
RK118D
ll'" & 1~"
Q
••
•• ••
& 3/8"
1/4" to 1/2"
21
j;l
...
1/2."
1"
R.K118Y
~IT
(J
~ en
.....
&
R.Kll90
~EPLAcruiENT PK16Y
1~"
l/4" & 3/ 8"
R.Kll9A
PANEL MOUNT
~ 15
SIZE
;! ~
1:} :c
•••
•••
••••
.')1
,...-,1"...-.
\ )
"
:1J
~
-~-~~---
-~
~
---··--~-
~~I""')
(')
(
\ /~
I
I. AMUliCAN NAfiONAl SlANOAHO lAPER PIPE
IIIHLAO~
(N.P.T.} I'll< ANSI U2.1-!96!l
2. VALVI:S AVAil AIHF Willi USP
-
z
c
'"
NOl£:
}>
•
[NO
HEX LOCK NUT
4 I DISC PLATE
i
BUNA N
ETH. PROP.
\I TON
BUNA N
ETH. PROP
\I TON
BRASS
sm. STL
COPPER
LEAD ALLOY
BUNA N
ETH. PROP
\I TON
BRASS
Sm. STL
BRASS
Sm. STL
6 IDISC
MAXIMUM WORKING PRESSURE (P.S.I)
PER MSS SP88 CLASS, CATEGORY B
_j~~-oo
25.4
4.75
--~--
120.6
I
...-.- •• ,...,,........,~
~,,,..,.,....
~24-ABS
42~-M l
424-MY-
*
T
7 IOISC HOLDER
,_'
8 !GASKET
INCHES
MILLIMETERS
9 lO-RING
10
LSEfo;:s~:~L:~~~~EB~OW
11 !DIAPHRAGM PtATE
SEE SHEET 424A
FOR OPTIONS
jll/.HEX LOCK NUT
I
JNUS-0010
424-K
424-KS
ORB-029
ORE-029
ORY 029
424 J
424 JE
424-JY
424 H
*
*
*
*
*
*
424
HS
200-GG
200-GCL
ORB-132
ORE-112
ORV 132
424-C
424-GS
424-D
424-DS
*
*
I
5
131cAP
M""
I
1
SCZ-00071 4
424-rB.
424-FV
424-R
141liEX HO. CAP SCREW (1/4-20 X 1 1/8
OUNA N/NYlOII
IS !DIAPHRAGM
\ITON/IlOMEX
COPPER
16IGASKET
LEAD ALLOY
o"t.iEX NUT (1/4-20
N
N
Ml
~24-AB5
CAST BRASS llf2•f:lf'f - -
5 lO-RING
oQ_[_
424-A5
SEAl
CAST BRASS
2 'SU ASSCIOllt¥
IOCI.S OCtOWlli:AST Sm Sfi - -
APPROX
25.4
'AA' "' ONj"'· OC<
I 11!: NP T
4. f. C. DENOTES MA TfRIAL 15 TEFL. ON COATED.
L_
"'
rl"+ ~2~-A6
I 1 ~ N.P.T.
i·.P2·
NP
CAST IRON
I BOO¥
('()"'" c I 0"' ll< I ' 2 1 1' 7J
' omL
I o-b I'
lJ
.
: ~
3. ETH. PROP. DENOTES ETHYlENE
PROPYLENE (MA"IERIAL).
~/)
~-"'"
M39
01
02
1-:
...
424--Rt.
*
II<UZ-00081 4
*
I
c
c
- . 8UNA N -~-~± .,ORB-I_!Ql'f
£Tii PROP.
ORE-110
\I TON~--- ORV-110
___
IBIO~·RING
19ISHAFT
~
424-L
...
REPAIR PARTS KITS
DESCRIPTION
DIAPHRAGM & SEAlS KIT
CONSISTS Of ITEM NOS
3, 5, 6, 8. 9, 12. 15, 16 & 18
INTERNAL PARTS KIT
NORMALLY OPt.N MODEL
(f)
I
fTI
Pl
424DV5 (1 1/4 N.P.T.)
-j
424DV6 (1 1/2" N.P.T.)
NORMALLY OPEN (STANDARD)
z
0
it;
.j:;.
j
~'
\..
PART NO
ETH. PROP.
\I TON
424-RB£
424-RBV
424-RA
(INCLUDES
424-fB
CONSISTS Of STANDARD ( *)
ITEM NOS 4,7,10.11.19
AND APPROPRIATE
•
"DIAPHRAGM AND SEALS KIT
INTERNAL PARTS KIT
NORMALLY CLOSED MOGEL
424 _RB
CONSISTS Of STANDARD ( *)
llfW NOS. 4.7.10.1i.25(SE£ Sll£[1 42<A)
AND APPROPRIATE
"DIAPHRAGM AND SEALS KIT"
4 2 4 -RC
U)
---1
)>
z
424-RCE
424-RCV
0
)>
::::0
0
AquaMatic
::UQ!l.M&LLQEftL
(PowER TO ct.osE) - uNE PREssuRE/FLow AGAINsT mE vALVE
SEATING OISC WILL OPEN THE VALVE.
CONTROL PRESSURE APPLIED TO THE TOP Of THE
DIAPHRAGM WILL CLOSE THE VALVE. (CONTROL PRESSURE SHOULO BE APPLIED AT POI<T "c".)
®
AOUAMAllC. INC.
ROCKfORD. IWNO<s
0
SERIES 424 STANOARO MOOEl
DIAPHRAGM VALVE (1 1/4. & 1 1/2• N.P.T.)
(Jl
~
I
BUNA N
REVISED ON 5-2-90 (ECN-0096)
!~r::: 19~'fs-881uWI'.
NU
~
0
0
fTI
C-424-113r'' 2 j
Figure 14
Your Vacutrans unit has been shipped almost completely
assembled.
In the box you should have received:
1.
Qty.
1 Vacutrans body assembly
2.
Qty.
1 ball valve/gauge assembly
3.
Qty.
1 camlock set for 2" hose
4.
Qty.
1 optional mounting stand for Vacutrans
To make your unit operational you must simply thread the
camlock hose fitting into the vacuum port, the 'ball
valve/gauge assembly into the Vacutrans body assembly, and
attach the optional mounting stand to the unit (if you wish).
CAMLOCK HOSE
FITTING
(H-012)
GAUGE
(V•2JO)
NOZZLE CASTING
{V·210)
VEN'fUR: CASTING
(V•llS)
RUBBER WASHER
{Part of v-2211
23
1;• BALL VI\LV£
{V·240)
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