K-Series Manual
Contents
1. Strainer Emergency Muffler Air Tank ri _____ Nozzle Compressed Air Supply Hose Control Handle Pressure Vessel Pinch Valve Blast Metering Valve DANGER Never attempt to open the Abrasive Blaster in any way while it is pressurized Use extreme caution when performing troubleshooting procedures that involve pressurizing the Abrasive Blaster Troubleshooting procedures are to be performed by experienced qualified personnel only BLAST MACHINE IS SLOW TO TURN OFF OR WILL NOT TURN OFF WHEN CONTROL HANDLE IS RELEASED Possible Causes 1 A bleeder type control handle has been installed WARNING Never use bleeder type Remote Control Handles such as Clemco or A BEC style handles with Pirate Brand KPH Series Blasters as they may cause the Abrasive Blaster to start without warning or to not stop the Abrasive Blaster when released 2 The Pneumatic Control Handle is damaged defective or worn out if equipped 3 The Electric Control Handle is damaged defective or worn out if equipped 4 The Electric Control Cord is damaged defective or worn out if equipped 5 The Control Valve is stuck or in need of service due to lack of lubrication or is damaged defective or worn out 6 400 Pinch Valve is stuck or in need of service due to lack of lubrication or is damaged defective or worn out 7 400 Pinch Valve does not have the required 100 PSI minimum supplied to the2. 001 YV lp Z 2 EMERGENCY AIR SUPPLY Allow this tank to become fully pressurize before opening Inlet valve to fill blaster NEVER operate the blaster with the drain open The Emergency Air Tank Drain must be COMPLETELY closed while in operation Severing Hazard Pop Up will forcefully MADE IN THE USA Instructions For Installing Replacement Label Pack 1 Completely remove old label and clean area thoroughly before applying new label 2 Apply replacement labels in locations as described above or as close as possible if area is obstructed 3 Placement of Inlet Label and Pressurized Hose labels will vary based on which type of system Place these labels as close to the inlet coupling as possible 4 12 VDC Label is only to be used on electric remote controlled systems DO NOT apply label to systems with pneumatic remote controls K Series Pressure Hold System WARNING This section of the manual is designed to give you a general understanding of how the Abrasive Blaster functions All sections of this manual must be read and understood before operating the equipment ADDING ABRASIVE Abrasive is added through the hole in the top of the Abrasive Blaster where the Pop up and its seat are located When abrasive is added it flows down through the hole around the Pop up and down to the bottom of the pressure vessel where it will exit through the Metering Valve when b
3. gt Flow of Exhaust Air During Blow down K Series Pressure Hold System Loaded Abrasive Outlet ee Valve nal oJ I ol A Exhausted Ar gt Emergency Muffler KT 22 RE 2 DE Compressed T Air Inlet Inlet Valve Choke Valve Pressure Vessel Pusher Pinch Line Valve W Jee 5 ri P IREE SIGE Air Mix Metering To Blasting Nozzle Valve WARNING The Procedures provided in the Operating Procedures section of the manual are designed to provide basic information on how to safely operate the features of Pirate Brand KPH Series Abrasive Blasters Only personnel thoroughly trained in abrasive blasting should operate the Abrasive Blaster SETTING UP THE BLASTER INSPECT PRESSURE VESSEL When you receive your Abrasive Blaster remove the Handway Assembly and check for foreign items that may have fallen into the Abrasive Blaster Remove any foreign materials and reinstall the Handway Assembly DANGER Never perform any maintenance or A attempt to open the Abrasive Blaster in any way while it is pressurized The violent release of compressed air and propelled objects will cause serious injury or death RE TIGHTEN HANDWAY ASSEMBLY After the Abrasive Blaster has been pressurized for the first time tighten the nuts on the Handway Asse
4. 888 2125 00009PB VALVE MANUAL PLUNGER GASKET N 888 2125 00610PB VALVE MANUAL PLUNGER PIPE NIPPLE 1 FEMALE x 1 1 2 MALE 10 888 2125 00710PB VALVE MANUAL PLUNGER PIPE NIPPLE 1 1 4 MALE x 1 1 2 MALE 888 2125 00810PB ae MANUAL PLUNGER PIPE NIPPLE 1 1 2 MALE x 1 1 2 BLAST HOSE Nozzles Not Included 3 4 BLAST HOSE ASSEMBLY 50 INCLUDES NOZZLE HOLDER 1 BLAST HOSE ASSEMBLY 50 INCLUDES NOZZLE HOLDER 1 1 4 BLAST HOSE ASSEMBLY 50 INCLUDES NOZZLE HOLDER 1 AIR HOSE ASSEMBLY 25 1 AIR HOSE ASSEMBLY 50 10 034BLK 050 4AL 3 4 EXTENSION HOSE ASSEMBLY 50 1 1 2 AIR HOSE ASSEMBLY 25 10 100BLK 050 4AL 1 EXTENSION HOSE ASSEMBLY 50 1 1 2 AIR HOSE ASSEMBLY 50 10 114BLK 050 4AL 1 1 4 EXTENSION HOSE ASSEMBLY 50 27WT 1 SAFETY CABLE 1 2 1 HOSE TO EQUIP SAFETY CABLE 1 2 1 HOSE TO EQUIP SAFETY CABLE 1 2 1 HOSE TO SAFETY CABLE 1 1 2 3 HOSE TO HOSE EQUIP SAFETY CABLE 1 1 4 HOSE TO HOSE 27WC 1 SAFETY CABLE 1 2 1 HOSE TO HOSE 27WT 2 SAFETY CABLE 1 1 2 3 HOSE TO SAFETY CABLE 1 1 4 3 HOSE 27WC 2 HOSE EQUIP NOZZLES 1 ENTRY NOZZLES FOR USE WITH 3 4 BLAST HOSE 1201 1172 3 TUNGSTEN CARBIDE NOZZLE 1201 1173 4 TUNGSTEN CARBIDE NOZZLE 1 ENTRY NOZZLES FOR USE WITH 1 BLAST HOSE 1201 1173 4 TUNGSTEN CARBIDE NOZZLE 1201 1174 5 TUNGSTEN CARBIDE NOZZLE 1201 1175 6 TUNGSTEN CARBIDE NOZZLE 1 1 4 ENTRY NOZZLES FOR USE WITH 1 1 4 BLAST HOS
5. USER S MANUAL 35 amp 65 CU FT KPH SERIES BLASTERS A WARNING These products and equipment are not under any circumstances to be used with sand or silica products of any type and use of such materials will void any warranty Also as with the use of any product or equipment you must be sure to use the proper safety equipment and to properly train your employees in the use of any equipment or products The manufacturer wholesaler and distributor assume no responsibility arising from the failure to use proper safety equipment or the failure to properly train employees in the use of products and equipment A WARNING Read Manual Failure to read understand amp follow all safety and operation procedures in this manual can Cause serious injury or death Manuals that are lost incomplete or damaged must be replaced immediately Manual P N PB MAK001 Manual Revision July 15 Copyright 2013 2015 Pirate Brand All Rights Reserved Thank you for your purchase of a Pirate Brand KPH Series Blaster It is important to note that all Pirate Brand blasting equipment is designed to be safe when used properly however misuse of any abrasive blasting equipment is dangerous and can result in the severe injury or death of the operator and others in the vicinity of the blasting equipment In order to protect yourself and those around you read and follow all sections of this manual amp warning labels located on t
6. CLEARANCE 44 OAH 18 4 600 6508 BOTTOM 7 1 2 CLEARANCE 51 OAH 24 DIA INCLUDES HANDWAY ASSEMBLY POP DIA INCLUDES HANDWAY ASSEMBLY POP UP POP UP GASKET SCREEN amp BAG UP POP UP GASKET SCREEN amp BAG BREAKER BREAKER PLUNGER SEALING COATED 6 GASKET HANDWAY 6 x 8 HANDWAY CRAB ASSY 6 x 8 AXLE 3 4 x 22 8 888 7040 006 1 x 33 LID 18 DIAW HANDLE POWDER COATED 9 888 5010 060PB LID 24 DIA W HANDLE POWDER COATED 102M3286 BRACKET MOUNTING FOR 400 PINCH VALVE INCLUDES ALL MOUNTING HARDWARE PB 662 10562 EMERGENCY AIR TANK MOUNTING BRACKET INCLUDES 2 BRACKETS AND ALL MOUNTING HARDWARE N J a a kb KPH SERIES Pneumatic Controls 3 5 CU FT MUFFLER BLOWDOWN 1 MNPT 6 5 CU FT VB100 BALL VALVE FULL PORT 1 NPT 888 3006 106PB ELBOW STREET 90 GALV 1 888 3029 10611 NIPPLE TBE GALV 1 3 UM 100 AIR COUPLING 2 LUG 1 MALE UF 125 NOT USED S583029 10799PB NIPPLE TBE GALV 11 CLOSED 868 3029 10600PB_ NIPPLE TBE GALV 1 CLOSED 8 5883029 10799PB NIPPLE TBE GALV 1 14 xCLOSED 286 3008 106P8 STREET o MOISTURE TRAP 1 1 M INLET x 1 1 4 M MOISTURE TRAP 1 1 4 1 1 4 M INLET x 1 888 1200 006 150 CFM POWDER COATED 888 1200 007PB P 1 4 OUTLET 150 CFM POWDER COATED BLACK BLA
7. Couplings amp Gaskets Every 8 Hours Of Use 4 Inspect Blasting Nozzle Every 8 Hours Of Use 5 Inspect Air Hose Couplings amp Gaskets Every 8 Hours Of Use 11 Service Control Valve Electric Models Descriptions of maintenance procedures referenced in this table are located on the next page Procedure Details 1 Inspect Personal Protective Equipment PPE Inspect ALL Personal Protective Equipment PPE for proper fit condition amp operation as designed Replace repair or be fitted as needed 2 Inspect Remote Control Handle and Control Hose Cord Pneumatic Remote Control Systems Inspect Control Handle for damage making sure the Safety Flap Lever Lock Button is in good working order and replace or repair as needed Inspect twinline hoses and replace if leaks areas that show abrasion or soft spots are found Electric Remote Control Systems Inspect Control Handle for damage making sure the switch and boot are in good working order and replace as needed Inspect control cord and replace if damaged plug ends areas that show abrasion exposed wires or cracks are found Always use the ball amp chain with the chain secured around the operators wrist Replace the ball amp chain assembly if lost or damaged 3 Inspect Blast Hose Couplings amp Gaskets Inspect Blast Hose for leaks abrasion amp soft spots and replace as needed Inspect couplings for damage leaks amp wear and replace as needed Inspect coupling gasket
8. PP P WARNING All those who will be in the area while blasting is to occur must be properly trained read the manual and be wearing safety equipment to protect from the hazards described by the WARNING and DANGER labels located on the Abrasive Blaster If any labels are worn or missing they must be replaced USING THE ABRASIVE BLASTER After pressurizing the Abrasive Blaster it is ready to begin blasting Activate the Remote Control Handle to start the flow of abrasive and compressed air Adjustments to the air abrasive mixture can be made by turning the handle on MPV Series Metering Valves For 100 Metering Valves the flow of abrasive can be increased by loosening the nuts on the top of the valve and decreased by tightening the nuts The nuts must be tightened or loosened equally and if they are loosened too far air will leak when pressurized There will be a delay between a change made at the Metering Valve and what comes out of the Nozzle depending on the length of Blast Hose being used Adjustments to the Metering Valve should only be made when Abrasive Blaster is not in operation To stop the flow of compressed air and abrasive deactivate the Remote Control Handle and blasting will stop after a short time How long it takes for blasting to stop will depend on the length of Blast Hose being used WARNING If the adjustment bolts are set too loose on the 100 Metering Valve air and abrasive can escape at high
9. DISCONNECTING AIR SUPPLY HOSE procedure described above Failure to do so can cause the hose to blow off violently injuring or killing nearby people Air Tank Er 3 Choke Valve J i e B Pusher Line Metering Valve Maintenance Schedule DANGER Never perform any maintenance or attempt to open the Abrasive Blaster in any way while it is pressurized The violent release of compressed air and propelled objects will cause serious injury or death WARNING Maintenance procedures are to be performed by experienced qualified personnel only Failure to perform maintenance procedures correctly at the intervals specified below can lead to performance problems and equipment failure and will void the equipment warranty Procedure to be Performed Maintenance Interval 1 Inspect Personal Protective Equipment PPE Every 8 Hours Of Use Including but not limited to Respirators Airline Filters Carbon Monoxide Monitors Hearing Protection Eye Protection Foot Protection Protective Clothing amp Gloves Reference www osha gov 29 CFR 1910 132 General Requirements PPE 29 CFR 1910 133 Eye PPE 29 CFR 1910 134 Respiratory PPE 29 CFR 1910 136 Feet PPE 29 CFR 1910 138 Protective Clothing amp Gloves PPE 26 CFR 1926 101 Hearing PPE E 2 Inspect Remote Control Handle and Control Hose Cord Every 8 Hours Of Use 3 Inspect Blast Hose
10. FT KPH 888 2003 007 1 1 4 REGULATOR 6 5 CU FT KPH C RELIEF VALVE KIT ADDING THIS ASME RELIEF VALVE KIT TO YOUR BLASTER CAN PREVENT DANGEROUS OVERPRESSURIZATION LOCAL CODES MAY REQUIRE A DIFFERENT VALVE 888 2470 00702 SMALL BLASTER RELIEF VALVE KIT SG cun BIG GUN BG GUN BLAST HOSE amp NOZZLES High Performance Blasting BIG GUN HOSES FOR STATIONARY BLASTERS WHERE ABRASIVE IS BEING FED FROM AN OVERHEAD SYSTEM THE UMBRELLA WILL KEEP EXCESS WEIGHT OFF OF THE POP UP ALLOWING IT TO FUNCTION PROPERLY REQUIRES REMOVAL OF THE BUILT IN BAG BREAKER AND SCREEN FOR BLASTERS EQUIPPED WITH AN ABRASIVE UMBRELLA USE THESE SCREENS TO KEEP DEBRIS FROM ENTERING THE PRESSURE VESSEL ONLY USED WITH KPH SERIES BLASTERS WHERE THE BAG BREAKER HAS BEEN REMOVED TO ACCOMIDATE AN ABRASIVE UMBRELLA SCREEN FOR 3 5 KPH ABRASIVE 888 5011 030PB BLASTERS SCREEN FOR 6 5 KPH ABRASIVE 888 501 1 060PB BLASTERS KEEP TRACK OF TIME SPENT ON A JOB AND TOTAL HOURS ON YOUR ABRASIVE BLASTER KNOW YOUR COST CONTROL YOUR COST amp SET UP A PREVENTATIVE MAINTENANCE PROGRAM FOR YOUR BLAST EQUIPMENT FOR KPH WITH PNEUMATIC CONTROLS ONLY ADD A POWER SUPPLY TO RUN ANY 12VDC ELECTRIC BLASTER ON COMMON 120AC OUTLET POWER POWERS UP TO 4 CONTROL VALVES AT ONE TIME POWER SUPPLY 120AC INPUT 12VDC 2 5 AMP OUTPUT 2 LUG FOR KPH 1 1 4 BLAST HOSE ASSEMBLY BIG GUN NOZZLES BIG GUN FULL FLOW W COUPLINGS INCLU
11. and use of common sense Safety equipment including but not limited to Hearing Eye Body and Lung protection are required Abrasive blasters and the objects being blasted can be heavy and can lead to severe injury or death if they fall over Always follow all safety requirements of OSHA and NIOSH Use only Genuine Pirate Brand replacement parts when performing maintenance on the Abrasive Blaster Do not modify the equipment for any reason Use of modified or non Pirate Brand parts can cause an unsafe situation and will void your warranty Never use malfunctioning or damaged equipment Before each use inspect the Abrasive Blaster for proper function Supply only cool dry compressed air that is free of debris to the Abrasive Blaster Moisture or debris that reaches the remote control system can cause an unsafe situation Do not supply compressed air to the blaster that exceeds 150 psi e Do not use abrasive blasters in areas that could be considered a hazardous location as described in the National Electric Code NFPA 70 Article 500 Never use the Abrasive Blaster in wet environments Always connect electrically controlled abrasive blasters to a Ground Fault Circuit Interrupter GFCI Using This Manual 2 Definition Of Terms 2 Safety Symbols 2 WARNINGS 3 Safety Label I
12. 9 5 pprasive bh 675 775 875 975 1060 1100 1350 1840 AR cu ftimin 10 70 20 215 240 255 35 405 7 _cummin 425 481 566 609 680 72 1146 jrorserower 7 16 inch 9 5 mm asrasive lbh 80 4 tan 1300 140019101800 2580 AR Leuftmin 20 225 20 275 300 340 430 540 HO Horsepower hp 45 50 5 6 70 7 95 120 1 2 inch 127mm aprasive 1200 1350 1500 1700 1850 2025 2525 3240 cuftimin 300 350 400 450 50 550 700 80 Horsepower CP 70 80 90 10 110 120 150 190 5 8 inch 16 eras ve bn 190 2200 2400 2700 3000 3300 4000 5200 AR Leuftmin 430 50 55 650 70 800 1100 1255 Horsepower tre 10 II 80 1 IYITTIWIOHKIWATI 3 4 inch 19 mm _ This table is to be used as reference only Actual results may vary depending on specific abrasive medium used This table is based on abrasive with bulk density of 100 pounds cubic foot
13. CK 14 15 16 18 9 888 3028 10711PB NIPPLE TBE SCHEDULE 80 GALV 1 1 4 x 3 888 3029 10699PB NIPPLE TBE GALV 1 x CLOSED 19 888 3029 10718PB NIPPLE TBE GALV 1 1 4 x 8 124 1670 PUSHER LINE KIT FLEX 1 x 20 OAL 24 124 1680 oo 111 7200 FITTING 1 MNPT x 1 M FLARE 122 5290 FITTING 1 1 4 MNPT x 1 1 4 M FLARE VC100 CHECK VALVE SWING 1 VC125 CHECK VALVE SWING 1 1 4 888 3028 10g0gpg TBE SCHEDULE 80 GALV 1 een 0 1 CLOSED 4 888 2125 106 24 888 2125 107 1 1 4 WURETHANE SLEEVE SB 2 IR 888 3026 10907 NIPPLE TBE SCHEDULE 80 GALV 1 x NIPPLE TBE SCHEDULE 80 GALV 1 1 4 x 888 3028 10699PB CLOSED 888 3028 10799PB CLOSED 888 3026 10806PB BUSHING GALV 1 1 2 x 1 1 4 10 10 888 4203 50202PB SWIVEL 90 1 4 MNPT x 1 4 F 34 888 4200 30202 36 888 3026 10402 38 888 4201 50202PB 39 888 2492 302 o 888 3031 30202PB HEX NIPPLE 1 4 NPT x 1 4 W BALL ST 1 HT 60100 888 2010 00901PB GAUGE PRESSURE 0 160 PSI PB 03352 PULL CORD DRAIN VALVE 888 2013 402PB DUST ELIMINATOR 1 4 MNPT 103 9850 VALVE DIAPHRAGM CONTROL 888 3031 31200 NIPPLE HEX 1 4 MNPT x 1 8 MNPT 888 4224 30002PB PLUG 1 4 888 4224 30102PB BRASS SOCKET 1 4 888 3026 50200PB BUSHING PLATED 1 4 x 1 8 NPT 200 055 HOSE TWINLINE CONTROL ASSEMBLY YEL YEL W BLACK STRIPE NOMINAL 3 16 ID x 55 888 2263 000PB HAN
14. DES 50 888 5001 305PB 5 BIG GUN TUNGSTEN CARBIDE 10 114BLK 050 3XAL BLACK BLAST HOSE 1 NOZZLE ALUMINUM FULL PORT QUICK 1 86 BIG GUN TUNGSTEN CARBIDE FULL PORT COUPLINGS ARE REQUIRED TO CONNECT COUPLER amp 1 ALUMINUM a i NOZZLE BIG GUN BLAST HOSE TO YOUR KPH BLASTER NOZZLE HOLDER 1 1 4 BLAST HOSE EXTENSION NOZZLE SB 4X AL COUPLING USE WITH 100 METERING VALVE ASSEMBLY BIG GUN FULL FLOW BLACK BLAST HOSE amp 2 1 1 2 ALUMINUM FULL PORT ALUMINUM FULL PORT QUICK 10 BIG GUN TUNGSTEN CARBIDE SB 3X A QUICK COUPLING USE WITH MPV NOTES NOTES Nozzle Air Power amp Abrasive Requirements NOZZLE PRESSURE O 2 5 2 Horsepower CP 175 2 25 3 35 4 6 1 8 inch 3 2 mm asrasive JR TR ISS 3 071 085 099 113 122 127 170 Horsepower 5 3 16 inch 48mm 150 20 215 24 260 320 kg hr 68 77 109 118 145 P E PK 5 HA Horsepower CS 25 _ 1 4 inch 746 89 969 119 1268 1342 1864 6 35 an HH AR 80 90 100 115 125 10 190 230 45 Horsepower CP 17 2 2 27 28 3 60 5 16 inch 8 mm _ euftimin 10 15 145 160 15 20 25 35 6 Horsepower CP 25 2 2 3 40 4 5 65 3 8 inch
15. DLE CONTROL PNEUMATIC DEADMAN CONTROL HANDLE 888 2263 001PB HANDLE CONTROL PNEUMATIC 2 DEADMAN CONTROL HANDLE 888 2263 002PB HANDLE CONTROL PNEUMATIC 3 DEADMAN CONTROL HANDLE 26 N 28 gt gt gt N PE gt N 3 44 45 46 47 48 49 0 See Valve Parts Lists Section for detailed parts list See Control Handle Parts Lists Section for detailed parts list 99 9 8 0 27 TA I 1 g W 22 27 KPH SERIES Electric Controls 3 5 CU FT MUFFLER BLOWDOWN 1 BALL VALVE FULL PORT 1 NPT 888 3006 106PB ELBOW STREET 90 GALV 1 888 3029 10611PB TBE GALV 1 x 3 UM 100 AIR HOSE COUPLING 2 LUG 1 MALE NPT 5 UF 125 ae CUP 6 5 888 2011 006 VB100 MOISTURE TRAP 1 1 4 1 1 4 M INLET x 1 MOISTURE TRAP 1 1 M INLET x 1 1 4 M a OUTLET 150 CFM POWDER COATED BLACK 888 1200 007 150 POWDER COATED 888 3031 31202PB 14 888 3000 107 15 888 3029 10711 16 888 3006 107 9 888 3029 10699 888 3029 10718 TBE GALV 1 1 4 x 8 0 124 1670 PUSHER LINE KIT FLEX 1 x 20 OAL 24 124 1680 PUSHER LINE KIT FLEX 1 1 4 x 20 OAL 24 888 1200 006 1 12 N 111 7200 FI
16. E 5 TUNGSTEN CARBIDE NOZZLE AIR DRYER ADPB 250 CFM 100 PSIG 6 TUNGSTEN CARBIDE NOZZLE 7 TUNGSTEN CARBIDE NOZZLE AIR DRYER ADPB 400 CFM 100 PSIG OR 574 CFM 150 PSIG 8 TUNGSTEN CARBIDE NOZZLE AIR DRYER ADBP 750 950 800 CFM 100 PSIG OR 1149 CFM 150 PSIG AIR DRYER ADPB 1200 CFM 100 PSIG OR 1723 CFM 150 PSIG AIR DRYER ADPB 1600 CFM 100 PSIG NOVA 36 d OR 2297 CFM 150 PSIG 1348 555 1348 556 1348 557 1348 558 BLAST SUIT LIGHTWEIGHT MEDIUM BLAST SUIT LIGHTWEIGHT LARGE 407200 RADEX CO MONITOR 120V DL sb saman ADEE COON ORE BLAST SUIT LIGHTWEIGHT XXL BLAST SUIT LIGHTWEIGHT XXXL RESPIRATOR PACKAGES INCLUDE RESPIRATOR HELMET 50 LUXURY DOUBLE PALMED LEATHER BREATHING AIR SUPPLY HOSE AND RADEX AIRLINE FILTER BLASTING WELDING GLOVES 99 Manual Revision July 15 28 Copyright 2013 2015 Pirate Brand All Rights Reserved LIDS ARE IMPORTANT FOR KEEPING MOISTURE FROM FALLING INTO THE ABRASIVE BLASTER IN OUTDOOR APPLICATIONS MOISTURE IN THE ABRASIVE BLASTER CAN CAUSE OBSTRUCTIONS IN THE METERING VALVE LEADING TO COSTLY DOWN TIME 888 5010 030PB LID FOR 3 5 KPH ABRASIVE BLASTERS 888 5010 060 LID FOR 6 5 KPH ABRASIVE BLASTERS B REGULATOR KITS ADDING A REGULATOR KIT TO YOUR ABRASIVE BLASTER WILL ALLOW YOU TO BLAST AT LOWER PRESSURES TO ACHIEVE CUSTOM FINISHES OR HELP CONTROL PROFILE 888 2003 006 1 REGULATOR 3 5 CU
17. NECTION WITH THE PRODUCT AND USE OR PERFORMANCE OF THE PRODUCTS EXCEPT AS EXPRESSLY PROVIDED HEREIN ARE FULLY DISCLAIMED AND EXCLUDED AND NO SELLER OR DISTRIBUTOR HAS ANY AUTHORITY TO MAKE ANY WARRANTY OR ASSUME ANY LIABILITY ON BEHALF OF THE MANUFACTURER IN CONNECTION WITH THE SALE OF THE PRODUCT EXCEPT AS STATED HEREIN AS A CONDITION OF THE PURCHASE PURCHASER AGREES THAT MANUFACTURER AND SELLER SHALL NOT UNDER ANY CIRCUMSTANCES BE LIABLE FOR ANY COST OF FREIGHT SHIPPING OR TRANSPORTATION LABOR SPECIAL CHARGES NORMAL MAINTENANCE SERVICES LOST OPERATING TIME LOSS OF USE LOST PROFITS LOSS OF GOODWILL CONSEQUENTIAL DAMAGES PUNITIVE OR EXEMPLARY DAMAGES OR OTHER DAMAGES OR LOSS OTHER THAN AS DESCRIBED HEREIN MANUFACTURER AND SELLER MAKE NO WARRANTY OF ANY KIND EXPRESS OR IMPLIED WITH RESPECT TO THE PRODUCTS AND SPECIFICALLY DISCLAIM ANY WARRANTY OF MERCHANTABILITY FITNESS FOR A PARTICULAR PURPOSE OR OTHER WARRANTY PURCHASER ASSUMES ALL RISK AND LIABILITY RESULTING FROM THE USE OF THE PRODUCTS PURCHASER FURTHER AGREES AS A CONDITION OF THE SALE AND THE USE OF THE PRODUCT THAT ANY DAMAGES OR RISK OF LOSS OTHER THAN AS DESCRIBED HEREIN ABOVE SHALL BE THE EXCLUSIVE RESPONSIBILITY OF THE PURCHASER AND NOT THE MANUFACTURER OR SELLER MANUFACTURER AND SELLER SHALL NOT BE LIABLE FOR ANY DAMAGES INCURRED BY ANY PERSON AS A RESULT OF MISUSE IMPROPER INSTALLATION IMPROPER APPLICATION IMPROPER OPERATION OF THE PRODUCTS NORMAL WEAR AND TEA
18. R ALTERATIONS OR MODIFICATIONS MADE TO THE PRODUCTS OR ACCIDENT THE USE OF REPLACEMENT PARTS NOT PROVIDED OR AUTHORIZED BY THE MANUFACTURER VOIDS ALL WARRANTIES A COMPLETELY FILLED OUT WARRANTY CARD MUST BE RETURNED TO THE MANUFACTURER WITHIN THIRTY 30 DAYS OF PURCHASE OF THE PRODUCT OR ALL WARRANTIES ARE VOID PRODUCT MUST BE MAINTAINED IN ACCORDANCE TO THE MAINTENANCE SCHEDULE PROVIDED IN THE PRODUCT MANUAL FAILURE TO MAINTAIN THE PRODUCT IN ACCORDANCE WITH THE MAINTENANCE SCHEDULE VOIDS ALL WARRANTIES THIS WARRANTY DOES NOT COVER FACTORY INSTALLED OR CUSTOMER INSTALLED ACCESSORIES WARRANTY CLAIMS Warranty claims must be submitted to the manufacturer within ten 10 days after failure of the product Contact information for warranty claims Forecast Sales Inc 2719 Tobey Dr Indianapolis IN 46219 317 829 0147 Effective July 8 2015 3 5 6 5 1 VESSEL PORTABLE 3 5 CU FT 100 VESSEL PORTABLE 6 5 CU FT 185 LITERS 150 PSI 10 3 BAR 110 CONE LITERS 150 PSI 10 3 BAR 110 CONE 300 350P BOTTOM 7 1 2 CLEARANCE 18 DIA 1 600 650P BOTTOM 7 1 2 CLEARANCE 24 DIA INCLUDES HANDWAY ASSEMBLY POP UP INCLUDES HANDWAY ASSEMBLY POP UP POP UP GASKET SCREEN amp BAG BREAKER POP UP GASKET SCREEN amp BAG BREAKER VESSEL STATIONARY 3 5 CU FT 100 VESSEL STATIONARY 6 5 CU FT 185 LITERS 150 PSI 10 3 BAR 110 CONE LITERS 150 PSI 10 3 BAR 110 CONE 1 300 3505 BOTTOM 7 1 2
19. TROL ELECTRIC 2 1 2 PART SEALED CONTROL CORD PB 31131 CONNECTOR REQUIRED WHEN USING STEEL ABRASIVES HANDLE CONTROL ELECTRIC 2 REPAIR KIT 888 2263 40199PB lt pes 1 2 amp 3 888 2263 00108PB HANDLE CONTROL 2 SAFETY FLAP 400 Pinch Valve 6 1P3 80 8 1 420 POWDER COATED 4 4 TOUGH 100 Metering Valve 1 10 VALVE 100 METERING COMPLETE 1 1 2 NPT INLET DONUT WASHER BASE 1 1 2 INLET 1MV 60 TOP THRD CPLG STD NPS ALUMINUM 2 SB 5 P 32 GASKET STANDARD 6f _ 2 1 2 NUT 8 MPV Manual Plunger Valve 888 2125 106PB VALVE MANUAL PLUNGER 1 W URETHANE SLEEVE 888 2125 107 VALVE MANUAL PLUNGER 1 1 4 W URETHANE SLEEVE 888 2125 108PB VALVE MANUAL PLUNGER 1 1 2 W URETHANE SLEEVE VALVE MANUAL PLUNGER REPAIR KIT W URETHANE SLEEVE 968 2125 10099PD INCLUDES 2 5 7 8 amp 9 9 Be 1 VALVE MANUAL PLUNGER SEAL W URETHANE SLEEVE 888 2125 10098 i DES 78589 1 888 2125 00001 VALVE MANUAL PLUNGER KNOB VALVE MANUAL PLUNGER ROLL PIN 888 2125 00004PB 888 7010 50556 VALVE MANUAL PLUNGER BOLT W WASHER 888 2125 00002 VALVE MANUAL PLUNGER CAP 888 2125 00005 VALVE MANUAL PLUNGER PLUNGER 888 2125 00006PB VALVE MANUAL PLUNGER BODY 888 2148 00006PB VALVE PLUNGER SEAL 888 2125 10008PB VALVE MANUAL PLUNGER SLEEVE URETHANE
20. TTING 1 MNPT x 1 M FLARE 122 5290 FITTING 1 1 4 MNPT x 1 1 4 M FLARE VC100 CHECK VALVE SWING 1 VC125 CHECK VALVE SWING 1 1 4 NIPPLE TBE SCHEDULE 80 GALV 1 x 3 888 3028 10699 CLOSED 23 24 888 2125 106 MPV 1 W URETHANE SLEEVE 24 888 2125 107PB 1 1 4 W URETHANE SLEEVE SB 2 IR 27 888 3026 10907 NIPPLE TBE SCHEDULE 80 GALV 1 x NIPPLE TBE SCHEDULE 80 GALV 1 1 4 x 28 888 3028 10699 CLOSED 888 3028 10799PB CLOSED 9 888 3026 10806 888 3026 10807 05 GALV 1 1 2 x 1 1 4 3 888 4203 50202PB 38 888 4201 50202PB 39 888 2492 302 HT 60100 888 3006 102PB ELBOW STREET 90 GALV 1 4 888 3014 102PB PIPE PLUG GALV 1 4 10 411 VALVE CONTROL 12 VDC 10 409 VALVE CONTROL END PLATE KIT 10 407 COIL CONTROL VALVE 12 VDC 10 418 VALVE CONTROL REPAIR KIT 40 101 K SERIES ELECTRIC CONTROL ASSEMBLY 12VDC W 2 LUG CONNECTORS 88282995 WEATHERPROOF COVER WITH 2 LUG TWIST LOCK FEMALE CONNECTOR 888 7173 055PB EXTN CORD W CONNECTORS 55 2 PRONG 2 WIRE 40 213 ELECTRIC SEALED REMOTE CONTROL SWITCH W BALL amp CHAIN 2 PRONG MALE CONNECTOR 888 7172 012PB POWER CORD 25 12VDC 2 LUG 10 352 FEMALE TWIST LOCK CONNECTOR 2 PRONG 10 354 MALE TWIST LOCK CONNECTOR 2 PRONG NOT USED N N N gt 5 7 8 9 O Q 2 Ullvi N 1 ep ee Valve Pa
21. ced by blasting with abrasives containing silica can cause respiratory disease Do not use abrasive containing silica under any circumstance even when respiratory protective equipment is being used Safety Symbols The safety symbols shown below exist for the safety and protection of the operator and those in the vicinity of the Abrasive Blaster The descriptions below explain how they are used in relation to the blasting equipment WARNING WARNING This symbol calls attention to a potentially hazardous situation that could result in serious injury or death if the instructions associated with the symbol are not followed The warning triangle will be displayed throughout the manual to denote instructions to which special attention should be paid A FE DANGER This symbol calls attention to a potentially hazardous situation that WILL result in serious injury or death if the instructions associated with the symbol are not followed The warning triangle will be displayed throughout the manual to denote instructions to which special attention should be paid WARNING A All persons who will be operating or will be in the vicinity of the Abrasive Blaster during its operation must receive proper training on how to safely operate the equipment and be informed of the potential hazards involved addition to proper training all persons who will be operating or will be in the vicinity of the Abrasive Blaster
22. during its operation must read understand and follow all procedures described in the user s manual For replacement manuals please contact your distributor or visit www pirate brand com e Respiratory protection is mandatory for all persons operating or located in the vicinity of the Abrasive Blaster Follow all OSHA and NIOSH requirements for breathing equipment and supplied air standards Pressurized Vessels contain large amounts of stored energy and can cause severe injury or death if safety procedures are not followed Never perform maintenance or attempt to open a Pressure Vessel for any reason while it is Pressurized Always Depressurize and properly disconnect equipment from its air source before performing any maintenance Do not modify grind or weld on the pressure vessel for any reason Doing so will void the ASME certification Do not use damaged pressure vessels e The use of proper remote control systems commonly referred to as Deadman controls are required when using abrasive blasters Never operate the Abrasive Blaster without remote controls Never use bleeder type control handles such as Clemco or A BEC style handles with KPH series blasters as they can cause a hazardous situation where the blaster will not shut off when the handle is released All persons who will be operating or will be in the vicinity of the Abrasive Blaster during its operation must protect themselves with the proper safety equipment
23. el location where all people in the vicinity are aware of its presence All necessary safety equipment 15 present and being worn by all people in the vicinity of the Abrasive Blaster Only personnel who have been thoroughly trained and have read and understand the manual are in the vicinity of the Abrasive Blaster When these conditions are met turn on the compressed air source Allow the Emergency Air Tank to become fully pressurized to at least 100 PSI 6 89 BAR before continuing Use the supplied pressure gauge on the emergency tank to check for pressurization Open the Inlet Valve on the Abrasive Blaster The Abrasive Blaster is now ready to begin blasting DANGER Never perform any maintenance or attempt to open the Abrasive Blaster in any way while it is pressurized The violent release of compressed air and propelled objects will cause serious injury or death DANGER Never supply compressed air exceeding 150 PSI 10 3 BAR to the Abrasive Blaster DANGER Never operate a KPH system if the Emergency Air Tank is not fully pressurized to at least 100 PSI If the Emergency Air Tank is found to not be holding pressure discontinue use of the blaster until repairs are made WARNING Blast Hose may kick back when Remote Control Handle is activated Be prepared and brace yourself for kick back Blasters with MPV Metering Valves or 100 Metering Valves will normally kick back erratically for a short time when started gt
24. end of the Blast Hose attach the Twinline Control Cord to the blast hose by wrapping duct tape around both every 3 feet 6 ww t Emergency Air Tank _ y Metering Valve BEFORE YOU BLAST PRE BLAST CHECK Before each use of the Abrasive Blaster it must be checked to ensure it is in safe condition to be used Closely examine all components of the Abrasive Blaster for signs of excessive wear worn out seals and hoses or damaged components If any component of the Abrasive Blaster is found to be damaged or worn it must be replaced before blasting A ADDING ABRASIVE Before filling the Abrasive Blaster make sure the inlet valve is closed and the pressure vessel is in a depressurized state Abrasive is added by pouring it into the top of the Abrasive Blaster where the abrasive can flow around the Pop up and into the pressure vessel Do not overfill the Abrasive Blaster Do not allow foreign materials to enter the Abrasive Blaster WARNING Never use an Abrasive Blaster if any components are damaged or worn Damaged or worn parts must be replaced before use DANGER Never reach into the Pop up opening while filling the Abrasive Blaster It can close without warning causing severe injury or death WARNING Pirate Brand Abrasive Blasters may not be used with abrasives containing silica Never use abrasives containing silica WARNING Never fill the abrasive blaster with the in
25. has been cleared If there is still an obstruction you must depressurize the Abrasive Blaster remove the pusher line and remove the Metering Valve to check for a steady stream of abrasive If the remaining abrasive in the pressure vessel does not flow freely out of the pressure vessel there is a large obstruction If abrasive flows wait until the Abrasive Blaster is empty before reinstalling the Metering Valve If you have determined there is a large obstruction then the obstruction must be removed from inside the Pressure Vessel To do this make sure the Abrasive Blaster is depressurized then remove the Handway Assembly Scoop or vacuum out all of the abrasive from inside the pressure vessel and remove the obstruction Reinstall the Handway Assembly and Metering Valve and tighten them securely then Refill the Abrasive Blaster 4 The Abrasive Blaster has wet abrasive in it The wet abrasive must be removed by depressurizing the Abrasive Blaster removing the Handway Assembly and scooping or vacuuming it out Dry abrasive must always be used Clean cool dry air must be supplied to the Abrasive Blaster in order to prevent the abrasive from getting wet Troubleshooting procedures are to be performed by experienced qualified personnel only ABRASIVE STREAM IS TOO HEAVY OR THROBBING WHEN BLASTING Possible Causes 1 Choke Valve is partially closed Never run the Abrasive Blaster with the Choke Valve in any other position except f
26. he blasting equipment Definition Of Terms Used In This Manual Abrasive A granular material used for blasting the surface of an object Also referred to as Media Blow down The automatic or manual release of air from a pressurized vessel Also referred to as Depressurize Control Handle A required device that allows the blaster to be remotely started and stopped Depressurize The automatic or manual release of air from a pressurized vessel Also known as Blow down Pressure Hold System Any blasting system in which the Pressure Vessel remains pressurized when the control handle is released Also known as a Manual Blow down System Pressure Release System Any blasting system in which the Pressure Vessel is automatically depressurized when the control handle is released Also known as an Automatic Blow down System Pressure Vessel The enclosed area of the blaster in which abrasive is contained and filled with pressurized air when blasting Pressurize To fill the pressure vessel with compressed Properly Trained A person who can be considered properly trained must have successfully completed a sandblasting training course that focuses on the safe operation of stationary or portable abrasive blasters in the 1 5 20 cu ft capacity range They must also have read and understood this manual in its entirety Silica A hazardous substance which is contained in many naturally occurring abrasives Dust produ
27. laster in any way while it is pressurized Use extreme A caution when performing troubleshooting procedures that involve pressurizing the Abrasive Blaster NO ABRASIVE FLOW WHEN BLASTING AIR ONLY Possible Causes 1 The Abrasive Blaster is empty or has no Abrasive in it 2 The Metering Valve is closed or has not been adjusted properly 3 There is an obstruction in the Metering Valve To clear the obstruction for MPV series amp 100 Metering Valves perform the following procedure MPV Valve Turn the knob on the Metering Valve clockwise until it stops and then turn the knob counter clockwise 9 full turns to open it completely 100 Metering Valve Depressurize the abrasive blaster Loosen but do not remove the adjustment bolts equally until they start to turn easily then tighten them both 1 full turn Repressurize the abrasive blaster WARNING If the adjustment bolts are set too loose A on the 100 Metering Valve air and abrasive can escape at high velocity around the donut washer injuring nearby personnel Depress the control handle and have a second qualified person close the choke valve for 2 seconds and then open it again immediately This will push minor obstructions such as a small amount of wet abrasive a piece of paper from a bag or bridged paint chips through the Metering Valve and out through the Nozzle Readjust the Metering Valve back to the desired setting for blasting and check to see if the obstruction
28. lasting is started PRESSURIZATION Before pressurization can take place in a pressure hold system the Blow down outlet Valve must be closed Then when a compressed air source such as air compressor is connected to the inlet of the Abrasive Blaster and turned on the Emergency Air Tank is pressurized and the Pinch Valve closes The Emergency Air Tank is a safety feature that will store a reserve of compressed air that will be available to keep the pinch valve closed in the event of a compressor failure When the Inlet Valve is opened compressed air can flow through the Moisture Separator and into the pressure vessel causing the Pop up located internally to seal against its seat allowing the pressure vessel to become pressurized When the control handle is activated a control valve allows the Pinch Valve to open allowing compressed air amp abrasive to flow and mix The mixture of compressed air and abrasive will now exit the Abrasive Blaster through the blast hose and nozzle connected to the coupling on the Metering Valve and blasting begins DEPRESSURIZATION BLOW DOWN When the control handle is released in a pressure hold KPH system the Pinch Valve closes and the pressure vessel remains filled with compressed air The compressed air remaining in the pressure vessel is released when the inlet valve is manually closed and the blow down outlet valve is manually opened gt Flow of Compressed Air gt Flow of Abrasive
29. let valve in the open position Always close the inlet valve before filling WARNING Electrically conductive abrasives may not be used with abrasive blasters using Electric Remote Control Systems without changing to sealed strain relief connectors WARNING Never attempt to move or transport the Abrasive Blaster when it contains Abrasive REMOTE CONTROL SYSTEM Abrasive Blasters must use a Remote Control System commonly known as deadman to start and stop abrasive blasting Remote Control Systems can be electric or pneumatic Electric Connect the Remote Control to the Abrasive Blaster s female twist lock connector Connect a 12 VDC power source 12V Battery or Optional 120 VAC to 12 VDC converter to the Abrasive Blaster s male twist lock connector Pneumatic Connect the Remote Control twinline hose to the quick disconnect fittings The twinline hose is supplied with different size fittings on each of the 2 lines to prevent them from being connected to the Abrasive Blaster incorrectly Do not modify or reverse these fittings It is not recommended that Pneumatic Remote Control Systems are used when the Blast Hose length will be longer than 100 feet WARNING Never operate the Abrasive Blaster without a Remote Control System WARNING Never use bleeder type Remote Control Handles such as Clemco or A BEC style handles with Pirate Brand KPH Series Equipment as they may cause the Abrasive Blaster to start without war
30. m from the emergency air tank Check the air lines to and from the emergency air tank for leaks Check the 90 Micron Strainer for clogging and clean or replace if necessary EMERGENCY AIR TANK DOES NOT HOLD PRESSURE See MAINTENANCE PROCEDURES section for diagnosis and repair information 3 WARRANTY 55 PIRATE BRAND ABRASIVE BLAST POT EQUIPMENT 5 YEAR 10 YEAR LIMITED WARRANTY 5 YEAR LIMITED ABRASIVE BLAST POT WARRANTY Manufacturer warrants the complete abrasive blast pot it manufactures to be free of defects in material and workmanship for a period of five 5 years from the date of invoice 10 YEAR LIMITED PRESSURE VESSEL WARRANTY Manufacturer warrants the abrasive blast pot pressure vessel it manufactures to be free of defects in material and workmanship for a period of ten 10 years from the date of invoice LIMITATION OF WARRANTIES AND REMEDIES THIS WARRANTY IS EXTENDED ONLY TO THE BUYER WHO PURCHASES THE ABRASIVE BLAST POT DIRECTLY FROM THE MANUFACTURER OR ITS AUTHORIZED DISTRIBUTORS AND IS NON TRANSFERABLE THE PURCHASER S EXCLUSIVE REMEDY ARISING FROM ITS PURCHASE OR USE OF THE PRODUCT SHALL BE STRICTLY LIMITED TO THE REPAIR OR REPLACEMENT OF THE PRODUCTS AT THE DISCRETION OF THE MANUFACTURER AND ALL WARRANTY CLAIMS OR REQUESTS MUST BE MADE IN WRITING TO THE MANUFACTURER WITHIN TEN 10 DAYS AFTER FAILURE OF THE PRODUCT ALL OBLIGATIONS OR LIABILITIES OF MANUFACTURER OR SELLER FOR DAMAGES ARISING OUT OF OR IN CON
31. mbly Tightening the nuts on the Handway Assembly should also be done any time after the Handway has been removed for maintenance before and after the next pressurization attempt to open the Abrasive Blaster in any way while it is pressurized The violent release of compressed air and propelled objects will cause serious injury or death DANGER Never perform any maintenance or Outlet Valve Muffler Nozzle Compressed Air Supply Hose Control Handle Pressure Vessel Pinch Valve ge Blast Hose PURGE AIR SUPPLY HOSE Before connecting the Air Supply Hose to the Abrasive Blaster purge the hose of any moisture or foreign debris Standing water or moisture in the air line will cause degraded performance of the Abrasive Blaster Air supplied to the Abrasive Blaster must be clean dry and cool ATTACH REMOTE CONTROL HANDLES Attach the Remote Control Handle to the Blast Hose near the Nozzle with hose clamps or heavy wire ties Form a loop of Twinline Control Cord that comes 6 away from the Blast Hose runs 6 parallel to the Blast Hose and comes 6 back to the Blast Hose Using duct tape attach the Twinline Control Cord to the Blast Hose where the loop ends by wrapping the tape around the Blast Hose twice and then around the Twinline Control Cord This creates a strain relief attachment and is only necessary on the first connection near the Control Handle Starting from the Nozzle
32. nformation 5 How KPH Systems 6 OPERATING PROCEDURES 8 Set Up 8 Before You Blast 9 Blasting 10 MAINTENANCE PROCEDURES 12 14 u ssss ae 16 Pressure Vessel Parts 17 Pipe String Parts 18 KPH SERIES Pneumatic Controls 18 19 KPH SERIES Electric Controls 20 21 Control Handle Parts Lists 22 Valve Parts Lists 23 Blasting Set Up 26 Available Accessories 28 Blasting GHGS 32 Distributed Contact Info For manual updates visit the Pirate Brand website at WWW PIRATE BRAND COM Space for Distributor 1 Explosion Hazard X2 6 Breathing Hazard 11 WARNING Label 16 12VDC Label 2 Severing Hazard X2 7 Hearing Hazard 12 Made In USA 17 Drain Label 3 Read Manual 8 Eye Hazard 13 Series Label 18 Pirate Brand Label 4 Crush Hazard 9 Pressurized Hose 14 Emergency Air Tank 19 Pinch Point 5 Inlet Label 10 Spray Hazard 15 Outlet Label A Labels must be replaced when they are no longer readable Replacement Label Pack P N
33. ning or to not stop the Abrasive Blaster when released WARNING Never reverse or modify pneumatic Remote Control twinline hose fittings DANGER Always use caution around electric sources to avoid electric shock Do not operate electrical remote controlled Abrasive Blasters in wet or other hazardous environments CONNECTING HOSES Before connecting hoses to the Abrasive Blaster make sure the Inlet Valve is closed and the compressed air supply is shut off Connect the hose coming from the compressed air supply to the inlet on the Abrasive Blaster and secure with safety clips Connect the blast hose to the coupling on the Metering Valve at the base of the Abrasive Blaster and secure with safety clips Use mechanics safety wire when using optional BIG GUN full port couplings WARNING Always use safety devices like clips and whip checks safety cables at hose connections Optional BIG GUN full port couplings require the use of safety mechanics wire for proper securing BLASTING PRESSURIZING THE ABRASIVE BLASTER Before pressurizing the Abrasive Blaster make sure the following conditions occur All BEFORE YOU BLAST procedures have been followed 9 The Inlet Valve is closed The Blow down Valve Outlet Valve is closed The Remote Control Handle is released All hose connections are secure and have safety clip or safety mechanics wire installed The Abrasive Blaster is set up in a safe and lev
34. rts Lists Section for detailed parts list PNEUMATIC REMOTE CONTROL HANDLE NOT FOR USE WITH STEEL ABRASIVES 888 2263 000 HANDLE CONTROL PNEUMATIC HANDLE CONTROL PNEUMATIC REPAIR KIT 888 2263 00099PB CLUDES 1 2 384 888 3031 30202 NIPPLE 1 4 NPT x 1 4 W BALL ST 6 888 3031 30000PB NIPPLE 1 8 NPT x 1 8 W BALL ST COMES STANDARD WITH PNEUMATIC KPH PNEUMATIC REMOTE CONTROL HANDLE 2 888 2263 001PB HANDLE CONTROL PNEUMATIC 2 HANDLE CONTROL PNEUMATIC 2 REPAIR 899 2263 O0 ISSER INCLUDES 1 2 amp 3 CONTROL PNEUMATIC 2 SAFETY 888 3031 30202 NIPPLE 1 4 NPT x 1 4 W BALL ST 5 888 3031 30000 NIPPLE 1 8 NPT x 1 8 W BALL ST PNEUMATIC REMOTE CONTROL HANDLE 3 NOT FOR USE WITH STEEL ABRASIVES 888 3031 30202 NIPPLE 1 4 NPT x 1 4 W BALL ST 888 3031 30000PB HEX NIPPLE 1 8 NPT x 1 8 W BALL ST COMES STANDARD WITH ELECTRIC KPH ELECTRIC SEALED REMOTE CONTROL SWITCH W BALL amp CHAIN ELECTRIC SEALED REMOTE CONTROL SWITCH W Fe BALL amp CHAIN 2 PRONG MALE CONNECTOR BALL amp CHAIN ONLY FOR ELECTRIC SEALED REMOTE 0216 CONTROL SWITCH 1 2 3 PART SEALED CONTROL CORD CONNECTOR REQUIRED WHEN USING STEEL ABRASIVES ELECTRIC REMOTE CONTROL HANDLE NOT FOR USE WITH STEEL ABRASIVES 888 2263 400PB HANDLE CONTROL ELECTRIC PB 31131 ELECTRIC REMOTE CONTROL HANDLE 2 888 2263 401PB HANDLE CON
35. s for leaks amp wear and replace as needed Always use safety clips amp whip checks safety cables at Blast Hose connections BIG GUN full port couplings require the use of safety mechanics wire for proper securing PAY SPECIAL ATTENTION TO THE SECTION OF BLAST HOSE WHICH COMES IN CONTACT WITH THE PINCH VALVE WHEN THIS AREA BECOMES WORN CRACKED OR SOFT REMOVE THE COUPLING TRIM THE BLAST HOSE BACK PAST THE WORN AREA AND REINSTALL THE COUPLING OR REPLACE ENTIRE BLAST HOSE 4 Inspect Blasting Nozzle Inspect the Blasting Nozzle for wear and proper bore diameter Replace the Blasting Nozzle when the bore diameter has worn to 1 16 wider than its original diameter Example replace a 5 nozzle 5 16 bore when the bore reaches 3 8 5 Inspect Air Hose Couplings amp Gaskets Inspect Air Hose for leaks abrasion amp soft spots and replace as needed Inspect couplings for damage leaks amp wear and replace as needed Inspect coupling gaskets for leaks amp wear and replace as needed Always use safety clips amp whip checks safety cables at Air Hose connections 6 Inspect Emergency Air Tank For Bleed Down After depressurizing the pressure vessel and disconnecting the air supply hose as described in the OPERATING PROCEDURES Section watch the pressure gauge on the Emergency Air Tank If the Emergency Air Tank system is working properly the pressure contained in the tank will not drop If it does discontinue use of the bla
36. st equipment until the problem is corrected Possible causes of bleed down are A The 400 Pinch Valve is leaking and need to be serviced B The Check Valve on the Emergency Air Tank is damaged defective or worn out and needs to be replaced C The Pull Cord Drain Valve is damaged defective or worn out and needs to be replaced D The air supply hose between the Emergency Air Tank and the 400 Pinch Valve or control valve on electric models is leaking 7 Inspect amp Clean Blow down Muffler Remove the Blow down muffler turn it upside down and tap on a hard surface to free trapped debris If muffler is clogged and can t be cleaned out sufficiently it must be replaced 8 Inspect Pop Up amp Pop Up Gasket Inspect the Pop Up amp Pop Up Gasket for wear and replace as necessary 9 Service 400 Pinch Valve Disassemble clean amp inspect the 400 Pinch Valve for proper operation and worn components Replace any worn components and lubricate with silicone grease before reassembling 10 Inspect Service Metering Valve Disassemble clean amp inspect the Metering Valve for proper operation and worn components Replace any worn components found 11 Service Control Valve Electric Models Disassemble clean amp inspect for proper operation and worn components Replace any worn components found Lubricate with silicone grease before reassembling Performance Related Issues DANGER Never attempt to open the Abrasive B
37. ufficient power to open electric control valves if equipped 11 The Electric Control Cord is damaged defective or worn out if equipped 12 Control Valve stuck or in need of service due to lack of lubrication or is damaged defective or worn out if equipped SAFETY TANK WILL NOT FILL OR IS SLOW TO FILL Possible Causes 1 90 micron strainer is clogged Operational Related Issues BLAST MACHINE TURNS ACCIDENTALLY OR WITHOUT WARNING Possible Causes 1 The safety flap lever or lock button on the Control Handle is damaged or missing 2 The Pneumatic Control Handle is damaged defective or worn out if equipped 3 A bleeder type control handle has been installed WARNING Never use bleeder type Remote Control Handles such as Clemco or A BEC style handles with Pirate Brand KPH Series Blasters as they may cause the Abrasive Blaster to start without warning or to not stop the Abrasive Blaster when released A 4 The Electric Control Handle is damaged defective or worn out if equipped 5 The Electric Control Cord is damaged defective or worn out if equipped 6 400 Pinch Valve does not have the required 100 PSI minimum supplied to them from the emergency air tank if equipped Check the air lines to and from the emergency air tank for leaks Check the 90 Micron Strainer for clogging and clean or replace if necessary Outlet Valve _ gt a
38. ully open or damage to the Abrasive Blaster will occur 2 The Metering Valve needs to be adjusted LOW PRESSURE AT THE NOZZLE Possible Causes 1 Air compressor is the wrong size too small or the load button has not been pushed or turned on 2 Nozzle is worn out and the compressor cannot keep up with the increased demand 3 Air supply hose to the blast machine is too small 4 There is a hole in the blast hose 5 Handway Assembly is leaking 6 Choke Valve is partially closed Never run the Abrasive Blaster with the Choke Valve in any other position except fully open or damage to the Abrasive Blaster will occur 7 Abrasive Metering Valve is open too far 8 Obstruction in Nozzle 9 Regulator needs adjustment if equipped ABRASIVE BLASTER WILL NOT TURN ON OR IS SLOW TO TURN ON Possible Causes 1 Air compressor is the wrong size too small or the load button has not been pushed or turned on 2 Nozzle is worn out and the compressor cannot keep up with the increased demand 3 Air supply hose to the blast machine is too small 4 Control hoses and or fittings are leaking 5 90 micron strainer clogged 6 Obstruction in Nozzle 7 The Pneumatic Control Handle is damaged defective or worn out if equipped 8 The Electric Control Handle is damaged defective or worn out if equipped 9 The Electric Control Coil is defective if equipped 10 Power Source battery or AC DC converter is not providing s
39. velocity around the donut washer injuring nearby personnel DANGER Airborne particles produced by abrasive blasting can cause respiratory disease All persons operating or located near the blasting site must wear approved NIOSH OSHA approved breathing equipment Never use abrasive containing silica WARNING Only personnel thoroughly trained in abrasive blasting should operate the Abrasive Blaster This manual only provides basic information on how to safely operate the features of Pirate Brand KPH Series Abrasive Blasters WARNING Never point the blast Nozzle at yourself other people or the Abrasive Blaster WARNING The Choke Valve must be completely open when blasting or damage to equipment will occur BLASTING DRAINING THE MOISTURE SEPARATOR During blasting the Moisture Separator must be periodically drained The best way to accomplish this is to leave the drain valve slightly open all the time so it constantly leaks air and forces moisture out WARNING The Abrasive Blaster must be A supplied with clean cool dry compressed air in order to function properly The included Moisture Separator on the abrasive blaster may not be sufficient to achieve this depending on the quality of the air being supplied SHUTTING DOWN THE ABRASIVE BLASTER When blasting is complete the Abrasive Blaster will need to be shut down Make sure the Remote Control Handles are released then close the Inlet Valve Slowly open the Blo
40. w down Valve to allow the compressed air stored in the Abrasive Blaster to escape Outlet oe Valve Muffler Nozzle Compressed Air Supply Hose Control Handle Pressure Vessel Pinch Valve Blast Hose Strainer DISCONNECTING THE AIR SUPPLY HOSE After the Abrasive Blaster has been depressurized and the Inlet Valve has been closed the Compressed Air Supply Hose may still contain pressure which must be released before disconnecting the hose To do this shut off the compressed air at its source and open the Drain Valve and Blow Down Valve on the Abrasive Blaster Slowly open the inlet valve on the Abrasive Blaster The compressed air stored in the Compressed Air Supply Hose can now escape through the Drain Valve When you no longer hear air escaping through the drain valve squeeze the Compressed Air Supply Hose to confirm the absence of compressed air After confirming the absence of compressed air in the Compressed Air Supply Hose it is ready to be disconnected The Emergency Air Tank should still be pressurized at this point and is ready for its required daily maintenance inspection see MAINTENANCE PROCEDURES section for details After performing the maintenance inspection The Emergency Air Tank drain may now be opened to drain any collected moisture and depressurize the emergency air tank DANGER Never disconnect any compressed air supply hose without first performing the
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