Академический Документы
Профессиональный Документы
Культура Документы
O. M. 22501
WARNING
PREFACE
GENERAL INSTRUCTIONS
WARNING
OPERATIONAL INSTRUCTIONS
WARNING
PREFACE
instrument should be used to determine when surrounding
atmosphere is clear of dust and safe to breathe.
WARNING
II
PREFACE
MAINTENANCE
WARNING
NOTICE
WARRANTY
The following is in lieu of all warranties express, implied or
statutory and in no event shall seller or its agents, successors,
nominees or assignees, or either, be liable for special or
consequential damage arising out of a breach of warranty. This
warranty does not apply to any damage or defect resulting
from negligent or improper assembly or use of any item by the
buyer or its agent or from alteration or attempted repair by any
person other than an authorized agent of seller. All used,
repaired, modified or altered items are purchased as is and
with all faults. In no event shall seller be liable for
consequential or incidental damages. The sole and exclusive
remedy of buyer for breach of warranty by seller shall be repair
or replacement of defective parts or, at sellers option, refund
PREFACE
1 Air Compressor
11. Silica-free Abrasive
5. ASME Coded
Blast Machine
7. Remote
Controls
3. NIOSH
Approved
Supplied-Air
Respirator
6. Air Line
Filter
10. Appropriately
Sized Nozzle
4. CPF Air-Filter
8. Blast Hose
9. Hose Couplings and
Safety Cables
IV
1.0
INTRODUCTION
1.1
Scope of manual
Page 1
CAUTION
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
WARNING
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
Safety Alerts
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.3
1.3.1
Components
Blast Machine
WARNING
Welding, grinding, or drilling on the blast
machine could weaken the vessel. Compressed
air pressure could cause a weakened blast
machine to rupture, resulting in death or
serious injury. Welding, grinding, or drilling on
the blast machine vessel, without a National
Board R stamp voids the ASME and National
Board certification.
Page 2
Optional Cover
Concave Filling Head
Exhaust Muffler
Optional Screen
Diaphragm Outlet Valve
Abrasive Trap
Optional Umbrella
Piston Outlet Valve
Pop-up Seal
Safety Petcock
Pop-up Guide
Inlet Valve
Pop-up Valve
Inspection Door
Choke Valve
FSV Abrasive
Metering Valve
Control Handle
Optional Quantum
Manual Metering
Valve
Lo-Pot
Metering Valve
Optional 04321
Manual Pinch Tube Grit Valve
Figure 1
WARNING
Excessive compressed air pressure could
cause a blast machine to rupture. To prevent
serious injury or death, do not exceed the rated
pressure of the blast machine vessel.
1.3.3
Remote Controls
WARNING
Never modify or substitute remote control
parts. Parts from other manufacturers are not
compatible with Clemco equipment. If ANY part
of the remote control system is altered,
involuntary activation, which may cause
serious injury, can occur.
Page 3
WARNING
Moist air that freezes could cause blockage at
the control handle or in the control lines.
Blockage could cause involuntary activation of
the remote controls, or prevent the controls
from deactivating upon release of the control
handle. This situation could result in serious
injury or death. If remote controls are operated
in freezing or near freezing weather, install a
Clemco Anti-Freeze Injector, stock no. 05537,
on the remote control air supply line.
1.3.3.4 TLR Remote Controls are pressure-releasestyle systems, which control the pressurization and
depressurization of the blast machine. Pressurization,
which starts blasting, occurs when the control handle is
pressed. Depressurization, which stops blasting, occurs
when the handle is released.
Inlet Valve
Twinline Hose Unions
Control Handle
Figure 2
Abrasive
Page 4
Abrasive Size
2.0
INITIAL SET-UP
2.1
Storage Hopper
Page 5
WARNING
Clemco supplies an exhaust muffler with all blast
machines of 2 cu. ft. capacity and larger. The
muffler reduces exhaust noise and prevents
abrasive from exhausting upward or sideways
into the air. When the blast machine is
depressurized, the muffler body pops up to
diffuse the air and abrasive. When the machine is
fully depressurized, the muffler body drops,
permitting trapped abrasive to empty. For the
muffler to work properly, it must be installed with
the body facing up, as shown in Figure 1.
If an application requires the muffler be removed,
the exhaust piping must be plumbed to direct
exhausting air in a direction that ensures no
persons will be exposed to possible injury from
high velocity air and abrasive, which escapes
when the blast machine is depressurized.
installation
procedures
Metering Valve
Note: Valve may differ
from that shown
18-Inch Hose
Hose Unions
ACS Switch
Figure 3
2.4
3.0
OPERATION
WARNING
3.1
WARNING
Failure to observe the following warnings
before transporting or moving a blast machine
could result in serious injury or death.
3.1.1
3.1.2
WARNING
Never attempt to manually move a blast
machine when it contains abrasive. Empty
machines, up to 6 cu. ft. capacity, may be
moved when the following criteria are met:
Page 7
WARNING
Do not manually move the machine on an
incline, or on a slippery or irregular surface that
could cause the operator to slip or lose
balance. Sudden weight shifts when the
machine is tilted on an incline, and slipping or
tripping while moving the machine will cause
the operator to lose control of the machine,
causing severe injury and property damage.
3.2
60
13
77
3
30
171
7
54
312
12
89
534
20
126
764
28
170
1032
38
224
1336
50
70
15
88
3.5
33
196
8
61
354
14
101
604
23
143
864
32
194
1176
44
252
1512
56
80
17
101
4
38
216
9
68
408
16
113
672
26
161
960
36
217
1312
49
280
1680
63
90
19
112
4.5
41
238
10
74
448
17
126
740
28
173
1052
39
240
1448
54
309
1856
69
100
20
123
5
45
264
10
81
494
18
137
812
31
196
1152
44
254
1584
57
338
2024
75
125
25
152
5.5
55
319
12
98
608
22
168
982
37
237
1393
52
314
1931
69
409
2459
90
140
28
169
6.5
61
353
14
108
676
24
186
1085
42
263
1538
59
347
2138
77
452
2718
101
Air, Power
and Abrasive
Requirements
Air (cfm)
Abrasive lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
Air (cfm)
Abrasive (lbs/hr)
Compressor (hp)
For nozzle sizes 3/8" to 1/2", blast machines should be equipped with 1-1/4" or larger piping and inlet valve to prevent
pressure loss.
Air requirements were measured by a flow meter under actual blasting conditions, and are therefore lower than figures for
air alone, with no abrasive.
Horsepower requirements are based on 4.5 cfm per horsepower.
Figures are for reference only, and may vary for different working conditions. Several variables, including metering valve
adjustments, can affect abrasive flow.
Figures show approximate compressed air and abrasive consumption when nozzles are new. Consumption will increase as
the nozzle wears.
Figure 4
2009 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 22501
Page 8
WARNING
To prevent severe injury from accidental
activation of the blast machine, open the safety
petcock when the blast machine is not in use.
Opening the petcock prevents unintentional
blasting. The control handle can not activate
the machine when the petcock is open.
3.2.11 Make sure that the remote control handle lever
is in the up (no blast) position, and that the handle lever
and safety lock move freely.
WARNING
Hose disconnection while under pressure could
cause serious injury or death. Use safety lockpins and safety cables on all coupling
connections to help prevent hose couplings
from accidental disconnection.
3.2.5 Connect the ends of the 50-foot twinline hose to
the unions on the 5-foot twinline hose. Either side of the
hose can be attached to either fitting.
3.2.6 Check to make sure that all fittings are secure.
Leaks will cause the system to malfunction.
3.2.7 Make sure that all blast hose and compressedair supply hose connections are secured with safety lock
pins and safety cables.
3.2.8 Make sure the choke valve is open (handle inline with the piping).
3.2.9 Close the abrasive metering valve. The closed
position for the FSV and Lo-Pot metering valves is when
the handle is all the way to either side of center. The
closed position for the optional manual PVR grit valve is
when the metering knob is turned fully clockwise.
3.2.10 Make sure that the safety petcock located on the
inlet valve is open. Open position is when the lever is inline with the petcock, as shown in Figure 5.
WARNING
A separate manual is supplied with the remote
control handle. Do not operate the machine
before reading the remote control handle
operating instructions.
3.2.12 Check to make sure that the handle lever will
not seal the opening on the control handle, unless the
safety lever lock is pulled down.
WARNING
Malfunctioning control handles could cause
unintentional actuation of a blast machine, or
prevent a machine from deactivating upon
release. Malfunctioning control handles must
be taken out of service immediately and
repaired or replaced. Serious injury or death
could result from unintentional blasting.
3.2.13 Close the air valve on the compressor. Start the
compressor, and bring it to operating temperature and
pressure. The pressure must be more than 50 psi, but
must not exceed the blast machines rated pressure.
3.2.14 Slowly open the compressor air valve to
pressurize the air supply line. Listen for noise that
indicates any open lines or leaks.
Open
Figure 5
WARNING
All persons except for the machine tender must
stay clear of the blast machine. The blast
operator may pressurize or depressurize the
machine at any time. The noise generated by
the sudden release of compressed air when the
machine is pressurized or depressurized, may
startle bystanders, and may vent abrasive
under pressure. Either condition could result in
injury. The machine tender must wear a
suitable, approved respirator, plus approved
eye, face, and hearing protection.
3.2.17 When the blast operator is ready to blast, either
the operator or the machine tender, while standing back
and facing away from the concave filling head of the
blast machine and the exhaust muffler, closes the safety
petcock, preparing the machine for remote activation by
the control handle. Air should be heard escaping from
the orifice under the control handle lever but nowhere
else. The noise from air escaping at the handle is an
audible signal that air is supplied to the blast machine,
and will activate if the control handle is pressed.
3.3
Page 9
3.4
Blasting
3.4.1
CAUTION
Be prepared for the recoil from the blast hose.
Blasting should begin within a few seconds
after pressing the control handle lever.
Blasting Attire
WARNING
Before blasting, test the coating and substrate
for toxic materials (such as lead or other heavy
metals, or asbestos). These hazards require
special measures to protect the operators and
the environment.
No dust is safe to breathe. Abrasive blasting
produces harmful dust. Failure to wear
approved respirators could result in serious
lung disease or death. Blast operators must
wear properly fitted and maintained NIOSHapproved, type-CE supplied-air respirators
approved for abrasive blasting.
During abrasive blasting, abrasive particles and
dust in the area around the blast machine and
blast nozzle become airborne. Everyone
working in the vicinity of abrasive blasting must
wear properly-maintained, NIOSH-approved,
respiratory protection appropriate for the job
site hazards.
Loud noise generated by the use of
compressed air could cause hearing damage.
Everyone in the blasting area must wear
approved eye and hearing protection.
WARNING
OSHA requires the use of remote controls on all
blast machines when an operator controls the
nozzle. To comply with OSHA regulations, the
remote control handle, which starts and stops
the flow of air and abrasive, must be held down
manually. Do not tie down the control handle
lever or attempt to bypass any part of the
remote control system. Doing so will defeat the
purpose of the fail-to-safe feature of the remote
control. Serious injury or death could result
from uncontrolled blasting. Ref. 29 CFR
1910.244 (b).
3.5
3.7
Page 10
WARNING
When approaching an idle blast machine, and
before loading the blast machine with abrasive,
always check to make sure the safety petcock
is open. If it is closed, open it while standing
back and facing away from the concave head
and exhaust muffler. This step is especially
important if one worker (a machine tender)
loads the machine with abrasive while another
worker (the blast operator) controls the
blasting. The blast operator could pressurize
the machine before the machine tender has
moved away from the machine. During
pressurization, abrasive could be forced out of
the top of the machine, and cause injury.
3.7.1 Load abrasive into the machine by pouring it into
the concave head. Use an optional screen placed over
the head to prevent objects from falling inside. Foreign
objects will jam the machine. Abrasive flows through the
filling port into the machine. Keep the abrasive level
below the pop-up valve. Abrasive resting on the pop-up
valve could be forced up and out of the top of the
machine when the machine is pressurized.
3.7.2 When the blast operator is ready, either the
operator or the machine tender, while standing back and
facing away from the blast machines concave filling
head and the exhaust muffler, closes the safety petcock.
3.8
3.6
Stop Blasting
4.0
4.1
Daily
4.1.1
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. Check that the threads
are not worn, and that the nozzle holder
securely grips the nozzle. The nozzle washer
must also be inspected for wear. Worn nozzle
washers cause thread erosion. A loose fitting
nozzle may eject from the holder under
pressure and could cause severe injury.
Shutdown
3.9.1
3.9.6
WARNING
3.9
PREVENTIVE MAINTENANCE
Page 11
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. Check that the threads
are not worn, and that the nozzle holder
securely grips the nozzle. The nozzle washer
must also be inspected for wear. Worn nozzle
washers cause thread erosion. A loose fitting
nozzle may eject from the holder under
pressure and could cause severe injury.
WARNING
Malfunctioning control handles could cause
unintentional actuation of a blast machine, or
prevent a machine from deactivating upon
release. Malfunctioning control handles must
be taken out of service immediately and
repaired or replaced. Serious injury or death
could result from unintentional blasting.
4.1.2
4.2
Weekly
4.2.1
WARNING
Leaks around couplings and nozzle holders
indicate worn or loose-fitting parts. Nozzle
holders and couplings that do not fit tight on
hose, and nozzles that do not fit tight in nozzle
holders could disconnect while under pressure.
Impact from nozzles, couplings, hoses, or
abrasive, from parts disconnected by pressure
during operation could cause severe injury.
4.3
Monthly inspection
4.3.1
4.2.2
Page 12
4.4
Lubrication
4.5.1 Once per week while the air is off, put one or
two drops of light weight machine oil in the inlet valve
through the safety petcock. This will lubricate the piston
and O-rings in the inlet and outlet valves.
5.0
Page 13
SERVICE MAINTENANCE
WARNING
Failure to observe the following before
performing any maintenance could cause
serious injury or death from the sudden release
of compressed air.
WARNING
The machines outlet must be pointed away
from any objects or persons. Stand clear of the
path of exiting abrasive. It may come out at
high velocity. Impact from exiting abrasive
could cause severe injury.
5.1.5 Close the choke valve and fully open the
abrasive metering valve. Pressurize the machine to
force out any damp abrasive.
5.1.6 When the obstruction has been removed,
depressurize the machine. Remove the nozzle and
nozzle washer, and reconnect the hose. Open the choke
valve and close the abrasive metering valve. Pressurize
the machine to clear the hose. When the hose is
cleared, depressurize the machine so the nozzle and
nozzle washer can be attached.
WARNING
The threads on the nozzle and nozzle holder
must be inspected each time the nozzle is
secured to the holder. Check that the threads
are not worn, and that the nozzle holder
securely holds the nozzle. The nozzle washer
must also be inspected for wear. Worn nozzle
washers could erode nozzle threads. A loose
fitting nozzle may eject under pressure and
could cause severe injury.
5.1.7 With the hose cleared, start the machine using
normal procedures.
5.2
Clearing obstructions in
metering valve and blast machine.
the
abrasive
5.3.2
Bottom Section
Top Section
Page 14
WARNING
The orifice fitting must not be removed,
modified, or substituted with another fitting.
Altering the orifice fitting may cause
involuntary activation of the blast machine or
some other malfunction, which could result in
serious injury or death.
5.4
5.6
5.7
Abrasive Trap
Control handle
5.8.
5.5
Page 15
5.10
Page 16
WARNING
Pop-up Valve
Pop-up Guide
Tighten
Loosen
Figure 6
5.8.5 Slide the new pop-up valve over the guide, then
screw the valve guide (with the pop-up valve on it) into
position inside the machine. Tighten the guide snug, but
not wrench-tight. Over-tightening the guide will make it
difficult to remove the next time the pop-up valve needs
replacement.
Welding Ring
1
1
1 /2 - 2 /2
Screw
Cap
Pop-up Valve
Element Body
Pop-up Guide
Screen
Figure 7
5.9
Guide Nut
O-Ring
Screw Hole
Seat
Guide
Lock-Nut
Figure 8
WARNING
Replace the guide and guide nut if the nut is not
tightly fused to the guide. A loose fitting nut
could work off the guide, permitting the muffler
assembly to launch under pressure, and cause
severe injury.
5.10.6 Clean parts to be reused, with a non-caustic
solvent or detergent, and dry thoroughly.
5.10.7 Reassemble, taking care to correctly insert the
screws in the seat plate. The screw holes are the three
closest to the center. See the illustration in Figure 8.
Page 17
6.1
Neither abrasive nor air comes out of the
nozzle while the machine is under pressure
6.1.1 Depressurize the blast machine. After the popup valve has dropped, remove the nozzle, and check it
for obstruction.
6.1.2 Make sure that both the abrasive metering valve
and choke valve are open.
6.2
metering
valve
for
WARNING
When installed on the machine, the muffler
must face up. The muffler reduces exhaust
noise, and prevents abrasive from exhausting
upward or sideways when the blast machine is
depressurized. To reduce risk of injury from
abrasive carried by high velocity air, the muffler
must be installed with the body facing up.
6.3
6.4
6.0
TROUBLESHOOTING
WARNING
To avoid serious injury, observe the following
when troubleshooting the machine and remote
controls.
Abrasive surging
6.5
6.6
6.7
Blast machine will not depressurize or
depressurizes too slowly.
6.7.1 Abrasive trap screen blocked, or abrasive trap
needs cleaning. Clean the trap at least twice daily
6.7.2
Page 18
7.0
REPLACEMENT PARTS
7.1
Description
Cover, for
14" diameter machine
16" diameter machine
20" diameter machine
24" diameter machine
30" diameter machine
Stock No.
......................................02334
......................................02335
......................................20358
......................................02336
......................................02337
7.2
Item Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Page 19
22
23
21
4
19
1
2
5
20
11
6
10
15
27
17, 18
9
13
16
26
25
24
12
8
7
14
Figure 9
7.3
7.5
Description
Stock No.
7.4
Item Description
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Stock No.
Page 20
1.
2.
3.
4.
5.
Stock No.
4
11
1
2
6
10
5
8
9
Figure 10
Figure 11
7.6
7.7
Item Description
(-)
1.
2.
3.
4.
5.
6.*
7.*
8.*
9.
10.
11.*
12.*
13.*
14.
15.*
16.
(-)
Stock No.
Page 21
Item Description
(-)
1.
2.
3.
4.
5.
6.*
7.*
8.
9.
10.*
11.*
12.*
13.
14.*
15.
(-)
Stock No.
1
1
15
2
16
2
15*
14
14*
13
12*
13*
9
9
3
3
4
4
11*
12*
10*
11*
10
6*
6*
7*
8*
5
7*
Figure 13
Figure 12
7.8
Item Description
(-)
1.
2.
3.
4.
5.
6.*
7.*
8.*
9.
10.*
11.*
12.*
(-)
7.9
Page 22
Item Description
(-)
1.
2.
3.
4.
5.
6.
7.
Stock No.
7
6
2
1
1
2
3
4
3
5
Figure 15
6*
8*
10*
11*
12*
Figure 14
Page 23
Stock No.
Item Description
(-)
1.
2.
3.
4.
5.
6.
7.
8.
Stock No.
5
3
3
2*
8*
1*
7
4
4
9*
5
2*
7
7
3
5
Figure 16
Figure 17
Stock No.
Page 24
22
18
1
25
20
3
21
19
25
2
14
8
27
11
17
12
3
7
26
5
16
15
13
6
10
24
28
23
Figure 18