RBC Installation Manual
Contents
1. Comments Req d 1 BB2 15 Blaster Tank 51001100 1 2 1 Safety Valve 51002102 1 3 BB2 Piston Assembly Complete 51011000 1 4 BB2 Seat 51012102 1 5 BB2 Piston 51012101 1 6 BB2 Piston O Ring 51012103 1 7 BB2 Piston Barrel Assembly 51012100 1 8 BB2 Accessory Kit Complete 51041100 1 9 72 Non Return Check Valve 02820315B 1 10 34 x Y2 BSP Reducing Nipple 02404555 1 11 34 BSP Tee 02410505 1 12 4 BSP Nipple 02404505 1 13 Diaphragm Valve RCA20T 51042100 1 14 BSP Nipple 02404305 1 15 Ball Valve Optional 02820305 1 16 BB2 Suspension Kit Complete 51071100 1 17 BB2 Suspension Bracket 51072100 1 18 BB2 Suspension Cable 51072106 1 19 M16 x25 Setscrew 02315610Z 4 20 M16 x50 Bolt Nut amp Washer 02315640Z 4 Revision J 22 06 03 2014 9 2 BB4 Big Blaster Parts TRANSITION PIPE 5 P No 51061105 Item Single Double Description Part Number 1 1 1 BB4 50 Blaster Tank 51001106 BB4 150 Blaster Tank 51001111 BB4 250 Blaster Tank 51001115 BB4 375 Blaster Tank 51001120 2 2 2 Tank Flange Gasket 51052209 3 1 Tank Flange Cover Plate 51002101 4 1 1 72 Safety Relief Valve 51002102 b 1 1 Bush 34 72 Reducing Gal 02392515G 6 1 1 Nipple 72 Reducing 02404555 7 1 1 Valve 75 Ball 02820305 8 16 16 Stud M16x60 8 8 blk Chamered 02323610 9 16 32 Screw M16x50 Hex ZP 02315640Z 10 32 64 Wash2. The Big Blaster Air Cannon pneumatic bulk material activating systems utilise the release of a volume of compressed air at very high speed This sudden release of energy is directed through a transition pipe into compacted or frozen material in a bin silo or stockpile to dislodge that material and restore flow Compressed air stored in the Big Blaster Air Cannon s reservoir is released via the exclusive piston valve The high speed of discharge around 0 15 seconds of the Big Blaster Air Cannon allows the released energy to be delivered as an explosive charge This initial shock dislodges the material whilst the expanding air then aerates the material encouraging it to flow freely through the discharge orifice Big Blaster Air Cannons are safe to operate being remote from personnel and causing no sparks or flame There is no damage to the structure since the blasters are designed to minimise recoil avoiding structural fatigue PRESSURE VESSEL SOLENOID OPERATED VALVE RUBBER SEAT PISTON SEAL RING PISTON H 17 gt ews A i il il Era ETE COMPRESSED AIR ENTERING THROUGH ACCESSORY KIT TO NOZZLE IN DUCT PUSHES PISTON AGAINS
3. 16 Diaphragm Valve RCA40T 51042110 1 17 BB6 Suspension Kit 51071110 1 18 BB6 Suspension Cable 51072111 1 19 BB6 Suspension Bracket 51072110 1 20 1 x 4 Reducing Nipple 02404630 1 21 1 2 Ball Valve 02820305 1 22 M16 x 30 Setscrew 023156104 8 23 M16 x 50 Bolt Nut and Washer 023156404 16 Note BB6 Piston Assembly is no longer available It has been supseded by the BB6 XHV Valve Assembly Some parts are still available Revision J 24 06 03 2014 SECTION 10 FINAL CHECKLIST Site Number Date Site Equipment No Location Site Contact Completed By Circle Yes or No Below Was equipment to ESS Specification Yes No Drawing No Ref Attached Yes No If No WHY Will this affect performance Yes No If Yes WHY Was this a standard O service LI inspection LI installation Yes No If No WHY Was work carried out as per procedure and JSA Yes No If No WHY Is equipment fit for commissioning Yes No If No WHY Was a final inspection carried out while plant was running Yes No If No WHY Has anything changed from previous service inspection installation Yes No If Yes WHAT Is equipment performance to Client expectations Yes No If No WHY ESS Signature Client Signature Revision J 25 06 03 2014
4. Piston fill hole plugged hole through Clean piston hole and check air piston filtration Tank drain plug s loose Tighten plug Tank punctured cracked etc Replace Tank 7 2 BIG BLASTER AIR CANNON DOES NOT DISCHARGE Diaphragm valve not connected Check to be sure air line connections properly are to correct port Diaphragm valve dirty or damaged Clean or replace diaphragm valve or diaphragm Diaphragm valve exhaust port Open port to atmosphere blocked Piston lodged in cylinder Relieve pressure in receiver Free piston and clean cylinder Check air filtration Solenoid valve not operating Check electrical signal If okay replace coil Revision J 19 06 03 2014 7 3 BIG BLASTER AIR CANNON DISCHARGE FORCE LOW POSSIBLE CAUSE REMEDY Low air pressure Check and increase pressure Big Blaster Air Cannon not Allow longer period between actuating completely filled before it discharges Big Blaster Material in tank Remove and clean Water accumulated in tank Drain tank and take measures to prevent moisture accumulation Piston leaking air past O ring or Replace piston assembly with piston seat due to damage exchange unit from ESS Optional Accessory Kit silencer Remove and clean or replace silencer partially blocked 7 4 BIG BLASTER AIR CANNON DOES NOT FILL FAST ENOUGH Air supply line too small Go to larger airline size Restriction in airline Trace airline to restriction and remove Check filtration R
5. 82 MACKAY B PR Phone 07 4952 4600 aget l PO Box 5755 Fax 07 4952 4717 Mackav Mail Centre QLD 4741 essmac esseng com au MAITLAND is eae Court Phone 02 4932 3544 ohnson Street Maitland NSW 2320 Fax 02 4932 3611 essmai esseng com au PERTH 9 po Phone 08 9370 3155 ayswater 26 Midas Road Fax 08 9272 5130 Malaga WA 6090 essper esseng com au TOWNSVILLE Unit 6 40 42 Carmel St Phone 07 4755 2776 Grant Fax 07 4779 6236 esstow esseng com au SOUTH AUSTRALIA 5 Cormorant Court Mobile 0408 948 175 Middleton SA 5213 esssa esseng com au VICTORIA Phone 03 9580 0388 Unit 4 314 Governor Road Fax 03 9587 5199 Braeside VIC 3195 essvic esseng com au WOLLONGONG Unit 1 20 Doyle Avenue Phone 02 4272 4422 Box 343 Fax 02 4272 4434 Unanderra NSW 2526 esswol esseng com au TOLL FREE 1800 074 446 FROM ANYWHERE IN AUSTRALIA VSS TOLL FREE 1800 300 877 Revision J 2 06 03 2014 WARRANTY NOTE ESS WARRANTS Big Blaster Air Cannon to be free of defects both in materials and workmanship for a period of 12 months from the date of despatch of the product from the ESS factory The warranty given by ESS in this regard will extend only to replacing or repairing product shown to be defective The warranty also is subject to the following restrictions a Installation of the product contrary to the instructions contained in the supplied manual will void such warranty absolutely b T
6. ES Big Blaster Air Cannon Engineering Services amp Supplies Pty Ltd Phone 1 800 074446 Visit our Web Site www esseng com au UM MARTIN 7 ENGINEERING Installation Operations Manual Revision Description of Change Changed By Date A Added Final Checklist AS 28 5 07 B Changed to Metric Tanks TT 15 12 08 C Updated Melbourne Address amp Removed SA Address SH 3 08 09 D Commisioning Section 5 added to manual CR 2608 SH 14 08 09 E Final Checklist Updated Items 4 amp 5 Reversed SH 15 04 10 F Section 9 item 1 BB2 50 should be BB2 15 KO 24 01 2011 G Removed Mt Isa s contact details KO 7 6 12 H Changed format of manual KO 21 02 13 Updated parts table on page 23 9 2 KO 7 3 13 J Updated Office Details KO 6 3 14 Revision J 1 06 03 2014 ENGINEERING SERVICES and SUPPLIES OFFICE DETAILS Location Address Phone amp Fax PCI Phone 07 5589 2000 CURRUMBIN ox Currumbin QLD 4223 PED 00 SSET BOT esscur esseng com au EMERALD Er il f E Roberts Street Phone 07 4982 4855 OX Emerald OLD 4720 Fax 07 4987 5118 esseme esseng com au GLADSTONE Eo cu DEDE Street Phone 07 4972 3759 OX Gladstone QLD 4680 FOX Ur AUS CBS essgla esseng com au KALGOORLIE A eae re Phone 08 9021 7991 algoorlie i PO Box 10471 Fax 08 9021 7291 Kalgoorlie WA 6433 esskal esseng com au KARRATHA Phone 08 9144 0689 Fax 08 9144 06
7. ON SAFETY INSTALLATION OPERATION COMMISSIONING PREVENTATIVE MAINTENANCE TROUBLE SHOOTING DIMENSIONS PARTS LIST FINAL CHECKLIST 06 03 2014 SECTION 1 INTRODUCTION 1 1 GENERAL INFORMATION ESS Engineering Services and Supplies Pty Ltd is the sole Licensed Manufacturer of Martin Big Blaster Air Cannons in Australia Martin Big Blaster Air Cannons feature the patented Mark III External Piston Assembly giving the Big Blaster amp the fastest discharge time available ensuring maximum effect from the stored air The Mark Ill Piston Assembly has the added bonuses of excellent reliability coupled with simplicity of maintenance The Big Blaster range of tanks was redesigned and converted to metric sizing in 2008 The following Big Blaster models are now available Replaces Tank Discharge Model Number Previous Model Capacity Orifice Size BB2 15 BB2 8 16 15 litres DN50 2 BB4 50 BB4 12 30 50 litres DN100 4 BB4 150 BB4 20 30 150 litres DN100 4 BB4 250 BB4 20 48 250 litres DN100 4 BB4 375 BB4 25 48 375 litres DN100 4 BB6 600 BB6 30 60 600 litres DN150 6 Big Blasters are designed to operate on plant compressed air in the range of 80 120 psi 550 820 kPa The safety valve is set to operate at 140 psi 970 kPa All Big Blaster Tanks are pressure vessels designed and manufactured to AS1210 1997 The appropriate vessel test certificates will be for
8. T RUBBER SEAT dha d 3 lu gt i qi ilg ONCE SEATED THE AIR PASSES THROUGH THE HOLE IN THE PISTON AND PRESSURISES THE VESSEL THE PISTON IS SEALED BY THE THE SOLENOID VALVE IS OPENED AND THE POCKET OF AIR BEHIND RUBBER SEAT AND THE SEAL RING SO NO AIR ESCAPES THE PISTON ESCAPES THE PISTON IS PUSHED BACK BY THE AIR IN THE VESSEL THE COMPRESSED AIR IN THE VESSEL DISCHARGES VIA THE BLAST PIPE TO THE BLAST NOZZLE Revision J 7 06 03 2014 SECTION 2 SAFETY IMPORTANT To guard against possible serious injury ensure the following rules are strictly adhered to 1 DO NOT under any circumstances attempt to operate pressurise or fire an unsecured blaster The blaster must be permanently mounted to a structure and all of the appropriate blast directing pipework connected to ensure that the blast effect is contained within the area where it is intended Before attempting any work or maintenance on a blaster ensure that all air pressure is drained from the blaster This is done by closing the isolating valve on the air supply to the blaster and opening the drain valve on the bottom of the blaster tank Allow all pressure to drain before attempting any disassembly Take appr
9. ation of Big Blasters on concrete hoppers is exactly the same as for steel hoppers except 3 3 1 A hole will need to be drilled through the concrete hopper wall Diameters required are BB2 70mm BB4 125mm BB6 175mm A mounting plate is welded to the transition pipe and then bolted with masonry anchors to the outside of the hopper wall after insertion of the pipe through the drilled hole Typical mount plates are BB2 225 x 225 x 6mm PL 4 only 16mm anchors BB4 400 400 x 10mm PL 8 only 16mm anchors BB6 500x 500 x 12mm PL 8 only 20mm anchors 3 3 2 The anchor bracket for the suspension kit will need to be masonry anchored to the wall above the Blaster Revision J 10 06 03 2014 SUSPENSION KIT BIG BLASTER EN ae TRANSITION PIPE THROUGH BOLTS log Pa 300 MIN L B 5 7 AN ke LONG RADIUS BEND WELD HOLE DRILLED E IN CONCRETE MOUNTING PLATE B 4 3 4 BLASTER INSTALLATION 3 4 1 3 4 2 3 4 3 Revision J Select a blaster remove the plastic wrapping and straps and remove the blaster from its pallets Using appropriate lifting gear see shipping weights hoist the blaster to the mounting position A blank gasket is supplied bolted to the discharge flange of the blaster and is there to prevent dirt ingress duri
10. bly has matching parts to provide long service The faulty piston assembly can be forwarded to ESS for refurbishing Refer to section 6 4 for disassembly procedure Also at this time inspect the interior of the pressure vessel and remove any scale build up etc Reinstall all bolts washers and torque bolts to 200Nm 150ft Ibs 16 06 03 2014 6 4 6 3 6 Check all electrical connections to be sure there are no loose connections or broken wires 6 3 7 Having completed above reconnect all the air lines and power source and cycle each blaster individually to be sure of proper operation while checking that they charge fully to line pressure DISASSEMBLY PROCEDURE If a fault is detected in the operation of the Blaster that requires the disassembly or replacement of the piston assembly discharge valve the following procedures should be followed Before commencing any work on the Blaster ensure that the incoming air supply has been isolated and that all air in the Blaster tank has been drained Disconnect the air supply lines to prevent accidental re pressurising 6 4 1 PISTON ASSEMBLY DISCHARGE VALVE REPLACEMENT A complete change out of the piston assembly is the quickest and easiest way to overcome a fault in the operation of the valve ESS can supply an exchange unit and then repair or re furbish the old unit at ESS factory The following procedure should be followed Isolate the Blaster as previously described Disconnect th
11. e air supply line from the non return valve on the accessory kit Disconnect the electrical supply from the diaphragm valve on the accessory kit Using a pipe wrench unscrew and remove the accessory kit from the end of the piston assembly Ensure that the Blaster tank is supported by a supplementary support at the lifting lug ESS Suspension Kit or similar then remove the 8 x M16 screws 4 screws for BB2 securing the piston assembly to the Blaster tank The Blaster tank will now be loose and suspended by the lifting lug only Be careful not to drop or lose the rubber seat Ensure that the piston assembly is supported especially in elevated positions Remove the 8 x M16 bolts 4 bolts for BB2 that attach the piston assembly to the transition pipe Remove the piston assembly Installation is a simple reversal of the previous steps 6 4 2 PISTON ASSEMBLY DISCHARGE VALVE DISASSEMBLY At times it may be necessary to inspect and or replace some of the internal components of the piston assembly in situ This is easily done as follows Note the model BB2 50 Big Blaster does not have a removable end cover on the piston assembly and can only be serviced by removal of the piston assembly as described in section 5 5 1 Isolate the Blaster as previously described If the air supply line and electrical connections are flexible and have sufficient slack they can be left connected Otherwise disconnect Remove the 8 x M16 bolts that attach the
12. e event that air from the diaphragm valve should create flying debris ROUTINE EXTERNAL INSPECTION MONTHLY 6 2 1 6 2 2 6 2 3 6 2 4 Inspect all air lines and air line connections for leaks Air hoses should be checked for deterioration Ensure hoses are secured Inspect accessory kits filter and regulators for correct operation Check operation of the Safety Valve by lifting the tab on the valve Drain accumulated moisture in the Blaster tank by cracking the drain valve If fitted inspect the silencer on the Accessory Kit If silencer is dirty isolate and drain the Blaster then remove and clean or replace the silencer 6 3 SHUTDOWN SERVICE SIX MONTHLY 6 3 1 6 3 2 6 3 3 6 3 4 6 3 5 Revision J Visually inspect each of the Big Blaster Air Cannons Isolate the air supply and drain blasters as described in the safety notes Allow any water to drain from blaster tanks and lines Check mounting at hopper to be sure there is no damage to mount plate welds or fixing screws Check suspension turnbuckle to ensure that it is taut and relieving the bulk of the blaster assembly weight Check diaphragm valve for loose screws and clean out any dirt accumulation Replace diaphragm or complete valve assembly if badly worn If leaks are detected from blaster during normal operation an exchange piston assembly should be installed We strongly recommend the use of exchange piston assemblies from ESS as each assem
13. er M16X30 Dia Eng ZP 02319616Z 11 16 16 Washer M16 H D ZP 02319617Z 12 32 48 Nut M16 Hex ZP 02311616Z 13 1 2 BB6 Piston Assy Complete Suit Tank Pre 06 08 51021100 1 2 BB4 Piston Assy Complete Suit Tank Pre 06 08 51021101 14 1 2 BB4 Seat 51022102 15 1 2 BB4 Piston UHMW 51022101 16 1 2 BB4 Piston Quad Ring 51022103 17 1 2 BB4 Piston Barrel 51022100 18 1 2 BB4 Barrel End Cover Plate 51022105 19 2 4 Gasket High Temp 100 NB Table E 51102244 20 1 2 Cap 1 Plastic BB4 02394605P 21 1 2 BB4 Adaptor 0 Ring 51092103 22 1 2 BB4 Adaptor Ring 51092101 23 1 2 BB4 Accessory Kit Specify Voltage 51041105 24 1 1 Blaster Suspension Assy Kit 1 Full 51072107 25 1 1 Blaster Suspension Assy Kit 1 Full 51072107 Revision J 23 06 03 2014 9 3 BB6 Big Blaster Parts TRANSITION PIPE P No 51061110 amp ltem Description Part Number Comments 1 BB6 600 Blaster Tank 51001125 1 2 1 Safety Valve 51002102 1 3 72 4 Reducing Bush 02392515 1 4 BB6 Piston Assembly Complete 51031100 1 5 BB6 Seat 51032102 1 6 BB6 Piston 51032101 1 7 BB6 Piston O Ring 51032103 1 8 BB6 Piston Barrel 51032100 1 9 BB6 Barrel End Gasket 51032104 1 10 BB6 Barrel End Cover Plate 51032105 1 11 BB6 Accessory kit Complete 51041110 1 12 Non Return Check Valve 02820315B 1 13 1 x 4 BSP Reducing Nipple 02404670 1 14 1 BSP Tee 02410635 1 15 1 BSP Nipple 02404665 1
14. estriction in diaphragm valve or Check both and remove blockage piston hole Check filtration Air compressor too small Go to larger air compressor IF YOU SHOULD REQUIRE ANY ASSISTANCE IN REGARD TO THE OPERATION AND OR THE MAINTENANCE OF THE BIG BLASTER AIR CANNON PLEASE DO NOT HESITATE TO CALL ESS FOR IMMEDIATE ATTENTION Revision J 20 06 03 2014 SECTION 8 DIMENSIONS DIM C DIM A TANK LENGTH SAFETY VALVE DIM G F DIM B TANK DIA NOMINAL BORE DM E PU DRAIN VALVE IOPTIONALI Dimension Model Tank A B D E F G Volume BB2 15 15litres 485 219 240 320 50 110 192 BB4 50 50 litres 762 314 370 476 100 220 200 BB4 150 150 litres 912 518 370 551 100 220 200 BB4 250 250 litres 1387 518 370 789 100 220 200 BB4 375 375 litres 1438 622 370 814 100 220 200 BB6 600 600 litres 1610 762 442 917 150 300 235 Notes e Dimensions are indicative only request certified drawings before designing applications e For Double Ended Blasters mirror the assembly about the centre line e Model BB2 50 Blaster does not have a removable end cover on the piston assembly Revision J 21 06 03 2014 SECTION 9 PARTS LISTS 9 1 BB2 8 16 Big Blaster Parts TRANSITION PIPE P No 51061100 Item Description Part Number No
15. he warranty will not extend to any liability for injuries incurred and which result from the use of the product contrary to the instructions in the manual c Save as prescribed by law ESS will not be liable for any damage sustained by a purchaser or a third party by way of consequential loss arising out of defects in the product You are asked to note that ESS offers purchasers a service whereby either a It will install the product and certify the correctness of such installation or b Certify the correctness or otherwise of the installation of the product by third parties This certification service is designed to ensure that you obtain the full benefit of the ESS warranty hereby provided If you would like to take advantage of the installation certification service provided please contact ESS regarding the service Refer to the Final Checklist at the back of this manual Visit the ESS website www esseng com au to register your product warranty THE CONTENTS OF THIS MANUAL ARE COPYRIGHT TO ESS ENGINEERING SERVICES AND SUPPLIES PTY LTD ALL RIGHTS RESERVED Information contained herein is for use in the operation of the Big Blaster Air Cannon purchased from ESS and cannot be passed on to any other party without express permission in writing from ESS Revision J 3 06 03 2014 INDEX SECTION 1 SECTION 2 SECTION 3 SECTION 4 SECTION 5 SECTION 6 SECTION 7 SECTION 8 SECTION 9 SECTION 10 Revision J INTRODUCTI
16. including supply of an automatic system to suit All other operational constraints are as for the manual system OPERATION OF DOUBLE ENDED BLASTERS As previously noted Double Ended Blasters should be treated as two separate Blasters This means that the two solenoid controlled valves are energised separately and are never operated simultaneously It is essential that only one end of the Double Ended Blaster is fired at a time and the Blaster must be given time to re fill before either the same end or the opposite end is fired Revision J 14 06 03 2014 SECTION 5 COMMISSIONING Ensure that all personnel are clear of the inside of the chute bin or silo where the Blaster s are installed Ensure that all access doors are closed and locked Ensure that warning signs are placed at any point where personnel can access the Blaster operating area ESS can provide adhesive signs Open the valve to supply compressed air to the Blaster s Listen for the sound of the Blasters filling this should cease within about 1 minute as the Blaster fills If the air running sound continues look for air leaks If air continues to run and no leaks can be found a piston may not have seated isolate and drain Blaster and follow maintenance procedure to dismantle valve assembly and remedy Once Blaster s have filled place controller in Manual mode and test fire first Blaster Listen for a crisp discharge and for subsequent re filling of B
17. lange failure or the like If attachment as above is not achievable the Blaster tank may be supported on a purpose built cradle support bracket or similar Ensure that the tank is secured to the cradle and the cradle is secured to structure but also ensure that there is room for pipe movement or expansion especially in high temperature applications Flexible pipe sections or rubber mounting pads may be used to achieve this Fit the safety valve mandatory to the top socket and drain valve recommended option to the bottom socket of the blaster Fit the accessory kit to the blaster and connect the air and electrical supplies 1 2 BSP mu AIR CONNECTION mall ELECTRICAL CONNECTION DIN PLUG dila wy T BSP NIPPLE ON END OF BLASTER ATTACHMENT AND CONNECTION OF ACCESSORY KIT NOTE 1 It is advisable to leave this step until just before commissioning to prevent accidental or unauthorised firing of the blasters NOTE 2 In cases where noise output needs to be minimised a silencer may be fitted to the pilot air discharge point of the diaphragm valve of the Accessory Kit This must be a free flow silencer and it must be inspected and cleaned regularly to ensure correct operation of the Big Blaster ESS part numbe
18. laster Repeat for all Blasters Place controller in Auto mode Observe operation of sequence during plant operation Ensure sequence initiates as required and that Blasters fire in correct sequence Inform production operators of Blaster operations and ensure they know to contact a trained service person if the Blasters cease to operate Untrained personnel should not attempt to modify or repair a non operational Blaster Follow all safety precautions outlined in the manual plus normal safe working procedures for compressed air devices for any future maintenance work If Blaster sequence operates correctly and Blasters fire as required but blockages or hang ups are not removed contact ESS for advice and assistance An in line lubricator unit should be placed in the air supply line to the Blaster s Adjust for very light lubrication If excess oil is discharged from the diaphragm valve pilot port reduce the oil feed rate Standard light compressed air tool oil is suitable for the Blasters Revision J 15 06 03 2014 SECTION 6 PREVENTATIVE MAINTENANCE 6 1 BIG BLASTER AIR CANNON SYSTEM The Big Blaster Air Cannon requires little maintenance however the following schedule of preventative maintenance is recommended to eliminate the possibility of system shutdown due to failure 6 2 IMPORTANT DO NOT discharge blaster while any person is inspecting device Eye protection should be worn by persons in the area of blaster in th
19. led as per the previously described procedures The minimum 300 mm vertical pipe run must be maintained from the highest blast point where blast points are not at the same level meaning that the pipe run to the lower Blaster will be longer Care must be taken to avoid inducing stresses into the Blaster discharge valve piston assembly when making the second pipe closure When connecting the compressed air supplies to each end of the Double Ended Blaster ensure that individual 72 lines are run to each end of the Blaster DO NOT Tee from one line as this may provide insufficient air to seat both pistons and air leakage may result Revision J 13 06 03 2014 SECTION 4 OPERATION 4 1 4 2 4 3 4 4 Big Blasters are designed to operate on plant compressed air in the range of 80 120 psi 550 820 kPa To fire a pressurised Big Blaster Air Cannon is simply a matter of energising the solenoid on the diaphragm valve of the accessory kit This allows the air on the accessory kit side of the piston to evacuate The pressure in the vessel immediately pushes the piston at high velocity to the lid end of the piston barrel allowing all of the compressed air in the vessel to escape through the discharge orifice All of this takes place in less than 0 15 seconds Refer to operating sketch in section 1 4 The solenoid can be supplied in a number of voltages to suit clients requirements with 240V AC being standard supply The
20. ng shipment Cut the centre out of the gasket so that it can be used to seal the blast pipe at the connection to the Blaster With the Blaster positioned over the selected transition pipe bolt a loose flange to the discharge flange of the Blaster Position the bolted flange over the transition pipe and lower until the top of the transition pipe enters about 6 8 mm inside the loose flange Level the Blaster tank rotate it to the desired position then tack weld the transition pipe to the loose flange Remove the bolts securing the loose flange to the Blaster and lift the Blaster clear Check that the loose flange is suitably located on the transition pipe then fully weld the flange to the pipe 11 06 03 2014 3 4 4 3 4 5 3 4 6 3 4 7 Revision J Insert the gasket on the flange then lower and fully bolt the Blaster to the transition pipe flange Even though the blaster self supports at this point an additional support at the lifting lug is required to minimise recoil during firing see typical installation sketches in 3 2 and 3 3 This is normally done using an appropriately rated chain or cable support combined with a turnbuckle anchored to an appropriate mounting bracket directly above the lifting lug The turnbuckle is adjusted to just relieve the weight of the blaster without placing stress on the valve flanges or pipework Ensure that the Blaster tank cannot move excessively in the event of a pipe weld failure bolted f
21. opriate means to ensure that the blaster cannot be repressurised whilst the maintenance work is in progress Before attempting ANY work which requires personnel to be in the area of the blast discharge nozzles i e inside the bin ensure that blasters are isolated and drained as described above Accidental firing of a blaster could result in serious injury to any personnel in close proximity to discharge nozzle Revision J 8 06 03 2014 SECTION 3 INSTALLATION IMPORTANT NOTE Sketches are provided within this manual that show typical Big Blaster installations Most applications however will be different in some way to this Unless you have already done so or you are duplicating an existing installation we strongly advise that you contact ESS for assistance ESS can provide you with a supplementary drawing that will show suggested Blaster positions mounting details and transition pipe details for your application ESS also has a range of special nozzles suitable for many applications including high temperature applications This equipment can enhance the effectiveness of the Big Blaster system ESS cannot guarantee the effectiveness of Blasters placed contrary to or without our recommendation 3 1 PRE INSTALLATION STEPS FOR STEEL BINS 3 1 1 Locate and mark points for installation of blaster pipes as per installation drawing or ESS instructions The transition pipe must come out of the bin horizontally or inclined upwards Pipe
22. piston assembly end cover plate to the valve body and remove the cover plate with the accessory kit attached Be careful not to damage air or electrical connections The exposed piston will be visible in the bore of the piston assembly A hole through the piston has a short threaded section to allow insertion of a long bolt to assist withdrawal of the piston Bolt sizes are M16 for BB4 and M20 for BB6 Revision J 17 06 03 2014 e Withdraw the piston Inspect and if necessary replace the piston and or the seal ring The rubber seat can be inspected but cannot be replaced without completely removing the piston assembly as described in 5 5 1 e Re assembly is the reverse of the above Lightly oil the bore of the valve before inserting the piston Be careful when inserting the piston past the seal ring gently rotate the piston whilst working it in to avoid rolling over the seal ring Oncompletion re pressurise the Blaster and check for leaks e Test fire the Blaster If operation is correct return to service Revision J 18 06 03 2014 SECTION 7 TROUBLE SHOOTING 7 1 BIG BLASTER AIR CANNON DOES NOT CHARGE i e fill with compressed air POSSIBLE CAUSE REMEDY Accessory kit installed incorrectly Re install following diagram Non return valve installed back to Re install correctly front Piston not sealing or O ring leaking Clean or replace piston or O ring Diaphragm valve not sealing Remove and replace rubber diaphragm
23. r 51092105 is available for BB4 model Big Blasters 12 06 03 2014 3 4 8 The Blasters are pre tested for leaks before leaving the factory Once the blaster is connected and pressurised it should be visually inspected for leaks at any of the site connection points safety valve drain valve accessory kit air supply line The blast transition pipes discharge pipework are not normally pressurised and therefore will not show any leaks except during firing the duration of which is less than one second Therefore only a very major leak in the transition pipework will be detectable or have any effect on the blast force LUBRICATION NOTE ESS strongly recommends installation of a filter lubricator unit in the air supply line to each Blaster to help prevent corrosion of the piston assembly barrel and ensure reliable operation Ensure that the filter lubricator unit is regularly serviced THE BLASTER IS NOW READY TO FIRE 3 5 DOUBLE ENDED BLASTERS ESS can supply the Big Blaster Air Cannon in optional Double Ended configuration This is effectively two Blasters sharing a single storage vessel and should be treated as two Blasters The Double Ended Blaster is suitable where blast points are close together allowing sharing of the vessel without long blast pipe runs Where blast points are more than 3 metres apart or are at substantially different heights single ended Blasters should be used The Double Ended Blaster should be instal
24. s below horizontal will suffer material build ups and subsequent loss of blaster power A minimum of 300mm vertical run is required to prevent material dust entering the piston assembly SUSPENSION KIT WELD NI BIG BLASTER BLASTER DISCHARGE VERTICALLY DOWNWARDS IF NOT POSSIBLE z CONTACT ESS 74 LONG RADIUS BEND WELD 7 TRANSITION PIPE COMPENSATING PLATE Revision J 9 06 03 2014 3 2 2 Cut a hole in the hopper large enough to allow insertion of the transition pipe at the desired angle This hole will probably be an ellipse the shape of which depends on the hopper angle and the transition angle If a compensating plate is to be used cut the hole in the bin slightly larger than that in the compensating plate 3 2 3 Tack weld the compensating plate in position if used NOTE the installation procedure of the transition pipe is the same with or without the compensating plate 3 2 4 Insert the transition pipe through the compensating plate to the distance indicated by the drawing or ESS instructions usually level with inside of bin wall Check that the other end i e Blaster end of the pipe is vertical then tack weld the pipe to the compensating plate NOTE Ensure that there is enough clearance from the hopper to install the blaster onto the pipe Fully weld compensating plate to hopper and pipe to compensating plate 3 3 PRE INSTALLATION STEPS FOR CONCRETE BINS Install
25. solenoid only needs to be energised for a maximum of about 0 5 seconds Any longer and compressed air is being vented to atmosphere for no reason and vessel refill is being delayed MANUAL OPERATION To operate a blaster manually switching is normally done by the use of a simple non retaining push button As soon as the blaster fires release the button Where multiple blasters are installed fire the lowest blaster first Allow a short period of time to allow the dislodged material to clear then fire the next lowest blaster and so on Always ensure that dislodged material has somewhere to go i e bin gates are open feeder belt is running etc Firing blasters into a closed bin may result in further material compaction in some materials or excessive material aeration in other materials Always allow at least 30 seconds between consecutive firings of the same blaster to allow vessel refill AUTOMATIC OPERATION Automatic control may be done using a number of switching devices including sequence timers and PLC s The same criteria are required to fire the blaster i e a signal of the appropriate voltage and maximum duration of 0 5 seconds Frequency of operation of Blasters depends entirely on plant requirements i e how soon the flow problem re emerges after having been cleared by the previous blaster operation Therefore cycle times will need to be adjustable ESS can advise and assist with your particular plant requirements
26. warded to the customer shortly after despatch of the blaster s 1 2 HIGH TEMPERATURE APPLICATIONS When used in high temperature applications and in some other specialised applications the Big Blaster Air Cannon may be supplied with the XHV discharge valve in place of the Mark III Piston Assembly The XHV Valve is easily identified by its cast aluminium surface finish and the large XHV letters in the side of the outer housing casting If the Big Blaster being installed has XHV Valve s read this manual in conjunction with the separate manual If the XHV manual is not available request a copy from your ESS representative Revision J 5 06 03 2014 1 3 PACKAGING The blasters are despatched individually mounted on a small timber or steel pallet to facilitate fork handling and are orientated with the vessel lifting lug at the top to allow crane handling if required The blasters are also plastic heat wrapped to ensure good weather resistance during handling and pre installation storage Approximate shipping weights of the Blaster assemblies are BB2 15 24 KG BB4 50 100 KG BB4 150 110 KG BB4 250 130 KG BB4 375 150 KG BB6 600 240 KG Revision J 6 06 03 2014 1 4 HOW THEY WORK To be installed in your plant is the most unique system for assisting the flow of bulk materials This equipment is engineered to provide years of dependable service if operated and maintained in accordance with the enclosed instructions
Download Pdf Manuals
Related Search