section i-iv front cover-index warnings

7/30/2019 Section I-IV Front Cover-Index Warnings

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Operations & Maintenance Manual

For

Gimsa Monclova SA de CV

SERIAL No. 0841

ABRASIVE BLAST SYSTEMS, LLC

250 S. Shiloh RdGarland, Tx 75042

(972) 205-9309


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SECTION I. HOUSEKEEPING PROCEDURES

SECTION II. OPERATING PROCEDURES

SECTION III. GENERAL MAINTENANCE PROCEDURES

SECTION IV. MAINTENANCE ADJUSTMENTS AND

PARTS REPLACEMENT PROCEDURES

A. Elevator Module Operation,

Maintenance and Adjustments

B. Elevator Head Section

C. Elevator Belt Installation / Repair

D. Drive Units - Operation,Maintenance and Adjustments

E. Rotary Screen Abrasive Separator

SECTION V. BLAST POT

SECTION VI. AIRLINE FILTER & CO-MONITOR

SECTION VII. DUST COLLECTOR OPERATION

AND INSTALLATION

SECTION VIII. DRAWINGS

A. General Arrangement Drawing,

Sub assembly details

B. Electrical Schematic Drawing

ABRASIVE BLAST SYSTEMS, LLC

INDEX

WARNINGS


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WARNINGThese products & equipment are not, under any circumstances,to be used with sand or silica products of any type, and use ofsuch materials will void warranty. Also, as with the use of anyproduct or equipment, you must be sure to use the proper safetyequipment, and to properly train your employees in the use ofany equipment or products. The manufacturer, wholesaler anddistributor assume no responsibility arising from the failure touse proper safety equipment or the failure to properly trainemployees in the use of the products and equipment.

e

WARNINGTHIS MANUAL CONTAINS SPECIFIC PRECAUTIONARYSTATEMENTS RELATIVE TO WORKER SAFETY IN

APPROPRIATE SECTIONS. READ THIS MANUALTHOROUGHLY AND COMPLY AS DIRECTED. IT IS IMPOSSIBLETO LIST ALL OF THE POTENTIAL HAZARDS OF DUSTCONTROL EQUIPMENT OR BLAST & RECLAIM SYSTEMS. IT ISIMPERATIVE THAT USE OF THE EQUIPMENT BE DISCUSSEDWITH AN ABRASIVE BLAST SYSTEMS REPRESENTATIVE.PERSONNEL INVOLVED WITH THE EQUIPMENT OR SYSTEMSSHOULD BE INSTRUCTED TO CONDUCT THEMSELVES IN A

SAFE MANNER.


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WARNING1. Operating blasting equipment without following written instructions and recommended safety

procedures could result in serious injury or death. Before using the equipment, read allinstructions, literature, owners manuals, labels, specifications and warnings sent with and affixedto the unit. If operation of the unit is unclear after reading the instruction manual, contact yoursupervisor for instructions.

2. It is the responsibility of the employer to read all labels, warnings and instructionsto usersof the equipment who are unable to read.Periodic inspections and instructions in the use of thisequipment should be made by supervisory personnel to assure the equipment is being properlyused and maintained.

3. To prevent delayed lung injury, do not use abrasives containing free silica. Personalprotective equipment is required for all abrasive blasting operations. Observe all applicablelocal, state and federal safety regulations in conjunction with air line filters and respiratoryprotection (Reference OSHA 29CFR1910.134.1910.1000 and all subsequent additions ormodifications).

4. OSHA regulations require the use of an approved breathing air compressor when usingNIOSH approved respirators. Before attaching breathing air lines to the compressor and air filter,determine that the compressor is rated suitable as a supply or breathing air entering therespirator(s). If an oil lubricated compressor is used, it shall have a high temperature orcarbon monoxide monitor alarm (or both). Gross contamination of the inlet air to the aircompressor or serious compressor malfunction will adversely affect the quality of the breathingairentering the respirator(s).

5. Al l personnel in the vicinity of abrasive blasting operations shouldwearNIOSH approved air fedrespirators, hoods or helmets.

6. Al l waysdepressurize any vessel before loading mediaorany maintenance is performed.

7. Never operate blasters without remote controls. OSHA regulations require remote controls onall blast machines. Failure to use remote controls can cause serious injury or death to theoperator(s) or other personnel in the blasting area. (Reference OSHA Specifications

29CFR1910.244(b) and all subsequent additions or modifications).

8. Do not modify or alter any equipment or controls without written consent from AbrasiveBlast Systems, LLC.

9. The use of modif ied remote controls or door limit switches can cause unintentional start-upwithout warning which can result in serious personal injury.

10.Periodically check all hoses and dead-man controls to see that they are in good condition.Repair or replace any valves, hoses or controls that show any sign of wear or leakage.


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WARNING-CONVEYOR SCREWS

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WARNING OPERATOR PROTECTIVE

EQUIPMENT

1


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WARNING


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WARNING


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WARNING


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WARNING


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(972) 205-9309

AIRBLAST RECLAMATION SYSTEM

SECTION I. HOUSEKEEPING PROCEDURES

1) Do all housekeeping following each shift.

2) Always run system during housekeeping cleanup procedures. Allow to run

after cleanup to empty all screws and elevator.

3) Clear away discharge from hoses and pipes each shift.

4) Make sure discharge pipes and hoses are clean and not clogged.

5) Make sure dust collector hopper is empty each shift.

6) Watch for good abrasive in dust collector discharge hopper. If excessive, a

line trap might be required.

7) Keep covers on all trash receptacles.

Do not let trash receptacles overfill.

9) Keep pieces of wire, steel, wood, paper and other large trash picked up and

kept out of system. Do not depend upon reclaim system to dispose of any

and all trash.

10) Keep all pit areas clean and dry. Moisture is hazardous to this system.

11) Keep all materials and objects away from inlet plenums.

12) Check and clean debris from rotary screen at end of each shift.

13) Check dust collector pressure gauge reading during cleanup.

DO NOT let reading exceed "6". (See SECTION VII - Dust Collector)

NOTE: The Pressure gauge should operate between 2 & 4 of static pressure

For most of the operating life of the filter elements

WARNINGAll motors should be locked-out at the disconnect during allmaintenance procedures.


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SECTION II. OPERATING PROCEDURES

1. Make sure pressure tank and abrasive storage hopper is full at the

beginning of each shift.

2. Always have system running during abrasive additions and clean-up.

3. Always run entire system during blasting and cleanup operations.

4. Make abrasive additions slowly as to not to overload the reclaim system.

5. Make sure the system does not overload during abrasive additions or by

dumping cleaned parts with voids which hold additional abrasive.

6. Keep abrasive 12" below separator lip after additions and cleanup have beenmade and elevated into hopper.

7. Check for full abrasive curtain in separator daily. Elevator must be runningfull load for this to occur, usually at cleanup or abrasive additions.

8. Check to see if good abrasive is coming out of trash pipe weekly after set

properly. Adjust slide gate on the back of the air wash separator accordingly.

1/4" is a large adjustment and it will take time for the results to surface. (See

SECTION IV. C-8 in Parts Book)

WARNINGThese products & equipment are not, under any circumstances,to be used with sand or silica products of any type, and use ofsuch materials will void warranty. Also, as with the use of anyproduct or equipment, you must be sure to use the proper safetyequipment, and to properly train your employees in the use of

any equipment or products. The manufacturer, wholesaler anddistributor assume no responsibility arising from the failure touse proper safety equipment or the failure to properly trainemployees in the use of the products and equipment.


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SECTION II. OPERATING PROCEDURES Continued

9. Be certain rotary screen is clear of debris before startup of each shift.

10. Always listen for squeaks, banging, etc. This could be a sign that a problem

is occurring with the mechanical system. Shut the equipment down and

identify the problem.

11. Keep all floor grate in proper position during operation.

12. Visually check for screw rotation. If they are not turning, find out why.

13. Do not allow screws to get bent out of round with debris.

14. Check for air leaks in system weekly.

15. Keep all covers on during operation.

16. Listen for elevator belt making excessive clanging. The belt needs to be

tightened or tracked properly if this occurs. (See SECTION IV. B - Elevator

Head Section # 1 in Parts Book)

17. Check elevator belt tracking weekly. The belt should remain on the center of

the head pulley while in operation. The take up adjustments on either side ofthe head pulley will adjust up/down to obtain proper tracking and belt tension.

18. Make sure all dust collector slide gates are open at all times, except when

emptying 55 gallon dust drums.

19. START system with Green Button at each station.

20. STOP system with each Red Pushbutton OFF station.

21. When any portion of this system fails, NEVER push electrical overload reset

buttons and continue blasting without contacting foreman and maintenanceto determine initial problem.

22. Only use RED mushroom emergency shut-off for emergencies.

23. Keep all interlocks and buttons clean and in working order.

24. Watch for excessive wear in all areas and provide added lining as necessary.

k;hjojno;Njo;ko;

WARNINGAll guards and cover plates need to be on the equipment prior tostarting the equipment.


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SECTION III. GENERAL MAINTENANCE PROCEDURES

1) Belt Tracking-Check elevatorbelt tracking once per weekafter it stabilizes. Check it dailyfor two (2) weeks after changingor adjusting. Center the belt

in the housing by tighteningor loosing the take-up bolts

2) Guards- Keepguards on chainsand cover plateson at all timesduring theoperation of theequipment.

3) Changing Lubricant (Do NOT change oil in sealed for life reducers)

drain out initial oil, flush out the worm gearcase with an approved nonflammable, non-toxic solvent,such as Lubriplate Syn Flush, Lubriplate Pure Flush,Whitmores Flushing Oil (#06802030) or MedallionFlushing Oil Kosher (#06812010), and refill. Thereafter,oil should be changed at least every 2,500 operatinghours (5,000 for synthetic oil lubricant) or every 6months (12 months for synthetic oil lubricant), whichever occurs first.

Make sure reducer is lubed prior to startup.

4) Adjustments- Only allow one individual to adjust the Air-washseparator and slide gate adjustments. It takes time for results tosurface. The separator abrasive curtain should be no thicker than 1/8thick.

Take-up Bolts

CHAIN GUARD ELEVATOR TOP VIEW

Rotary Screen

After the first 100 hours of operation,


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4) Adjustments- Continue

Note 1/8" Curtain shown in redNote the "Full width" Curtain

Keep full abrasive curtain. Setaccording to dimensions shownon the following pageRotaryScreenAbrasiveSeparator)


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5) Wear- Watch for wear areas.Add lining to prevent excessivemaintenance and wear.

7) Auger damage- Watch for bent

screws. Debris that falls into thescrew hoppers (ie. Large bolts,steel angle etc. can causescrew to bend. This can be prevented easily!

8) Noise- Listen for squeaks and excessive scraping, and isolate theproblem. Remove debris.

9) Walking screws- Watch screw positioning and make sure they donot shift in positioning. They will always shift in the opposite directionof the abrasive flow. This is due to loose-set screws in bearings

extreme overloading, or loose locking collar on the shafts positionedon the ends of the screw. The screw should be repositioned. Loosenall connections and walk the screw back to its original position. Oncein position, tighten all connections and locking collars.

Set screws

Locking collar

10) Rotary screen Clogging- Check rotaryscreen for clogging and loose debris.

11) Chains- Check all chain tightnessmonthly.

12) Reclaim Bearings-

Do not grease bearings.They are all slow in revolutionand they are pre-lubricated andsealed for life.

13) Fan Bearings- Dust collector fanbearings require lubrication onceevery four months due to high RPM. (1750)

Chain


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A. ELEVATOR MODULE OPERATION,

1) Boot pulley- is rubber lagged and should be in goodcondition.

2) Adjustments- Adjust boot pulley belt tracking by using shimsbetween mounting angle bracket and pillow block bearing. Makesure you use shim plates. Do not use washers. This isnecessary only when alignment problems exist that cant beresolved by adjusting the take up bolts on the head section.

3) Bearings- Bearings are pre-lubricated and sealed for life. Donot grease.

4) Dust Leakage- Seal removable doors to minimizeabrasive leakage.

5) Rubbing- Make sure elevatorbelt does not rub side wallsof housing. It will usually favorone side. Adjust from headsection (Top PortionTake-Up bolts)

SECTION IV. MAINTENANCE ADJUSTMENTS AND REPLACEMENTS

A ELEVATOR MODULE BOOT SECTION: OPERATION, MAINTENANCE AND ADJUSTMENTS

Rubber laggedBoot Pulley

Use shimsbetween

mountingangle and

pillow block

bearing

An example of rubbing

NOTE: damagecaused by rubbing


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1) Take-Up adjustment- Head pulley take-upcontrols both the belt tension and beltcenter in housing. This take-up iscontrolled by loosening or tighteningthe take-up bolts on each side of the

head section from the top of theelevator.

2) Pulley- The head pulley must be rubberlagged and crowned for proper operation.This pulley is a one piece solid castassembly.

Take-up Bolts

B ELEVATOR MODULE HEAD SECTION

3) Oil-(Do NOT change oil in sealed

Make sure that Mobil 600WCylinder (460 wt.) oil is used.Mobil SHC 634 (460 wt.) is asynthetic oil that canbe used for hightemperature applications.The reducers box lubricantis used. New units usuallyrequire lubricant.

Rubber lagged

Head Pulley

4) Belt center- Make sure the elevator belt is centered in both the headand boot section of the elevator.

5) Noisy elevator- If buckets constantly hit the elevator housing, the

belt requires tightening and/or tracking.

6) Belt tension- Proper tension is the elimination of bucket housingclanging. Do not over tighten

7) Elevator alignment- Make sure elevator is in perfect plumb prior tostart-up

8) Loose buckets- Do not allow buckets to fall off elevator belts.

sealed for life reducers)


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C ELEVATOR MODULE BELT INSTALLATION, MAINTENANCE AND ADJUSTMENTS

a) Hang belt (bucketsfacing proper direction).Buckets will feed intothe separator screw.

b) Attach stretchingbrackets to bucketseach side of pulley.

c) Stretch with "comealong" until quitetight.

d) Locate clamps squareto belt and tighten totop of head pulley.

e) Clamp with vice grips,etc.

f) Drill and tighten two(2) or more bolts.

g) Remove vise gripsand finish drilling andbolting process.

h) Trim off excess beltsmooth with beltclamp belt face.

i) Add buckets at regularintervals to fill in voidif splicing existing belt.

j) Make sure belt tensionand tracking is setproperly prior to operation.

k) Make sure the elevator beltis centered in both the headand boot section of the elevator.

Note Bucket rotation direction

EXAMPLE of centered belt

EXAMPLE: Installed Belt splice

EXAMPLE: Installed Belt splic


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D DRIVE UNITS (ALL) - OPERATION, MAINTENANCE AND ADJUSTMENTS

1) Chain tightness- Keep chains tight with adjustable device suppliedwith units or use half (1/2) links whenever feasible.

2) Changing Lubricant (Do NOT change oil in sealed for life reducers)After the first 100 hours of operation, drain out initial oil,

flush out the worm gear case with an approved nonflammable,non-toxic solvent, such as Lubriplate Syn Flush, Lubriplate Pure Flush,

Whitmores Flushing Oil (#06802030) or MedallionFlushing OilKosher (#06812010), and refill. Thereafter, oil should be changed atleast every 2,500 operating hours (5,000 for synthetic oil lubricant) orevery 6 months (12 months for synthetic oil lubricant), whichever occurs first.

3) Oil-(Do NOT change oil in sealed for life reducers)Make sure that Mobil 600W Cylinder(460 wt.) oil is used.

Mobil SHC 634 (460 wt.) is a synthetic oil that

can be used for high temperature applications.The reducers box lubricant is used.New

4) Sprocket alignment- Make sure that drive sprockets arein-line with driven sprockets.

5) Reducer base- Make sure

WARNINGAll motors should be locked-out at the disconnect

during all maintenance procedures.

that the reducer mountingbracket is secure to the base.

6) Housekeeping- Clean abrasiveand debris out of drive pits.

7) Water damage- Make sure thatno water is entering into the pits

that will damage the equipment. Ifwater is present a sump pumpshould be positioned in theelevator pit recess area to pumpthe reclaim pits dry.

EXAMPLE: Water can damage your equipmen

WARNINGWater will damage reclaim components. Keep all areas dry andfree of debris.

units usuallyrequire lubricant.


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E AIR WASH SEPARATOR WITH ROTARY SCALPING DRUM: OPERATION, MAINTENANCE

AND ADJUSTMENTS

1) Rubbing- Make sure no rubbing occurs with housing duringoperation.

6 Flex hose fromDust collectorSlide gate

Rotary Screen

2) Clogging- Make sure it does not clog. Clean debris from drum if suchoccurs.

3) 2/3rd Baffle location- Make sure 2/3rd baffle is located towardelevator side of separator.

Elevator is to the right


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4) 2/3rd Baffle adjustment- Set 2/3 baffle 3/8" above angle of reposeof abrasive. Make sure it is parallel.

5) Swing Baffle adjustment- Set swing baffle so 1/8" clearance existsbelow bottom of baffle and separator lip. This distance is set accordingto abrasive size. Do not allow jams. The Baffle must swing easily andclear any obstructions.

6) Swing Baffle- Make sure Swing baffle hangs in a vertical position.

7) Counter weights- Adjustcounterweight on the swingbaffle (See green arrow) so

that it holds back abrasiveflow until a full width curtainof abrasive is obtained.Remove some weights

Note the "Full width" Curtain

if required, especiallywith lighter abrasives.


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8) Slide gate adjustment-Adjust slide gatebehind separator to remove desiredcontamination and spent abrasive.Do not pull out excessive good

abrasive. If too much good abrasiveis being removed, slightly close theslide gate. Note: Small increments(i.e. ) are large adjustments.

9) Adjustable baffle- Set bottom adjustable baffle lip so that 1/2" existsbetween edge of abrasive curtain and face of lip. This adjustment isvery important and changes drastically with steel grit, Garnet, Coal

slag, etc. `

10) Abrasive level- Check abrasive level each shift. By adding newabrasive into the system on a regular basis, you will have a moreconsistent blasting profile.

12) Airflow- Do not cover opening in front of separator. The unit is pullingin air to clean the abrasive.

section i-iv front cover-index warnings

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