THE WETBLASTING PROCESS

Wetblasting is the propulsion of a mixture of water and abrasive (a slurry) via

a blast nozzle, which on impact cleans, degreases and removes debris.

The water media slurry is contained within the cabinet sump, delivery of the
slurry to the manual blast nozzle is via a glandless polyurethane pump which
is submerged and externally driven using an electric motor. When the slurry
is pumped to the blast gun it is accelerated using compressed air to provide
the cleaning effect.

After contact/impact with the components the slurry then drains back into the
sump, creating a recirculating system. Fine broken down media and other
contaminants are fed via an overflow to a sedimentation filter unit positioned
at the rear of the machine.

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01642 769333 • SALES • SERVICE • SPARES • MEDIA
 SECTION 1

INSTALLATION

The Aquablast machine range does not normally require bolting to the floor
except in special build units which may be unstable. INSTALLATION AND
ANY NECESSARY GUARDING ARE NOT THE RESPONSIBILITY OF THE
MANUFACTURER. The commissioning of the machine once installed should
be carried out by a Vixen sales or service engineer or in conjunction with
advice from our factory.

1.1 GENERAL INSTRUCTIONS

A The machine should be sited on a firm, level base capable of

supporting the weight of the machine and the component loads not
forgetting the water and abrasive weight also. In most cases the
machine would be free standing.

B The sedimentation box is normally situated at the back of the machine

as near to the overflow as possible therefore preventing long lengths of
tubing which may block.

C Water connection – the Aquablast requires a mains water connection to

the rear of the machine. The mains water normally feeds the window
wash and the hand operated rinse gun, which is also used to re-fill the
machine with water.

D Vapour Vent – The machine has a 100mm circular vent fitted at the
back on the top of the machine, this allows the machine not to have a
positive pressure inside the blast machine. The 100mm vent can have
a plastic extension pipe and adapter fitted which is supplied separately,
this prevents vapour debris falling onto the top of the machine. It is also
possible (but rarely required) to connect the vent to an external wall via
the extension pipe if required in “clean room” situations for example.

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1.2 ELECTRICAL

A A standard Aquablast cabinet should be connected to a 25amp 3 phase

neutral & earth supply (including 3kw heater). Alternatively the machine
can be supplied single phase, in this case the machine using the
inverter can operate from a 16amp 240V single phase supply
(excluding 3kw heater).

B The pump motor is connected to the mains control panel by a small

socket connection externally mounted on the plastic case. This can be
unplugged allowing the pump and motor assembly to be carried to a
bench for service without disconnecting any wiring.

C All electrical supplies and connections are the responsibility of the user.
If on site any wiring connections are not suitable to the environment
then this modification is not the manufacturer’s responsibility.

WARNING: WITH 3 PHASE UNITS IT IS VITAL THAT THE

DIRECTION OF THE MOTOR IS CHECKED BEFORE FILLING THE
MACHINE WITH WATER.

RUNNING THE MACHINE IN THE WRONG DIRECTION WITH WATER

WILL UNSCREW THE IMPELLER IN THE PUMP AND WILL REQUIRE
DISMANTELING.

Procedure to check the rotation of the motor

 Be sure that there is no water in the hopper
 Find a co-worker to “bump” the footswitch as you watch for rotation
 Looking down on the motor, watch for the fan to turn clockwise
 Watch carefully and ask your co-worker to tap the footswitch quickly
 Repeat this procedure to be sure of the rotation
 If the rotation is clockwise you are “phased” properly
 If the rotation is counter clockwise, swap two three phase wires
 Check the rotation again after swapping to three phase wires.

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1.3 COMPRESSED AIR

A The Aquablast machine requires a compressed air supply to operate.

The compressed air requirement depends on the blast gun nozzle size
and the pressure required to clean effectively.

It is not normal to clean using air pressures greater than 60psi (4.5 bar)
as the greater the air pressure the more vapour generated and visibility
is impaired. Therefore to increase cleaning efficiency from the standard
nozzle usually fitted (12.5mm) then a larger 14mm nozzle can be fitted
with a larger air jet using a greater volume of air.

Typical air volumes are detailed in section 3.1

B The compressed air inlet connection is located inside the right leg of the
machine as you stand in front.

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 SECTION 2
2.1 PRINCIPAL OF THE AQUABLAST

ADDING WATER AND MEDIA The operating water level is at the lower level
of the overflow coupling in the hopper (See schematic above). Fill the hopper
with water but fill to 20mm (Approx .75 inches) below the desired level of the
coupling to allow for elevation due to adding the media. If this fill is the first fill
and your machine is new do not add the media until you have proven the
operation of all functions of the machine. Once proven, add media.

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OFF At the off position the machine is at rest with only the water heater and
cabinet lighting switched on.

Note: The hopper heater is for water temperature comfort only as some
machines are located in cold environments. The heater may aid in removing
oils in cold environments but it in no way enhances the blast process. In order
to save energy, it should only be used in cold environment’s.

When the machine is stood for thirty seconds or so, the media separates from
the slurry and will settle at the base of the machine hopper. The liquid will be
above which has the benefit of easy replacement when over contaminated.
The liquid only may be drained through the upper ball valve (No. 11 on G.A.
drawing) and afterwards re-filled using the mains water hand gun, in the
cases of a closed loop system then the machine will require filling from an
external hosepipe. Finally after re-filling a rust inhibitor/detergent maybe
added if required.

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2.2 PRINCIPLE OF THE AQUABLAST

INITIAL RUNNING Once the foot pedal is depressed the machine begins to
operate. Make sure that the operator has a firm hold of the blast gun at this
point otherwise damage to the machine may occur due to the blast gun
moving due to water pressure! When the machine is running the electric
window wiper and wash operate simultaneously with the pneumatically
driven pump, a solenoid valve opens also allowing the compressed air to the
blast gun. It is normal during the first few seconds (10-20) that the gun is only
propelling water mainly until the water agitation nozzle mixes both the water
and abrasive properly.

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2.3 PRINCIPLE OF THE AQUABLAST

RUNNING After initial running the water and abrasive are now fully mixed to a
slurry and the window wash will be adding mains water to the sump, all be it
at only a few litres /hour.

Note: Be sure that the window rinse nozzle is placed directly on the window
as it may have shifted in transit. The nozzle is NOT intended to “spray” water
at the window. A very slow flow that adheres to the window as it flows
downward is most desirable. The adjustment knob is conveniently located to
the left of the wiper. Check this flow rate daily.

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This additional water will exit the machine via the overflow. Typically small
broken down media floating near the top of the water level will be finer than
near the pump inlet. This water overflowing then will contain mostly debris
and unwanted abrasive and can be disposed of through the sedimentation
box. The free standing sedimentation box can be emptied periodically firstly
by draining the water off and disposing of, and then emptying the box of
debris and broken down blast media.

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SEDIMENTATION FILTER AND CLOSED
LOOP RINSE
The purpose of the sedimentation filter is to separate solid particles from the
water coming out of the overflow. It is inevitable that with the window washer
and the mains water rinse gun using mains water that over hours of blasting
the water level would increase if no overflow was fitted. The overflow serves
another purpose though in bringing debris and soils out of the slurry which
would otherwise over contaminate the blasting water slurry solution. There
are two types of overflow systems.

A Standard Open Drain Overflow

This system simply has the sedimentation box situated at the rear of the
machine and accepts water via the overflow into the sedimentation box.
The baffle within this box retains particles of abrasive (usually broken
down) together with debris and soils which is removed when blasting.
The debris settles to the base of the sedimentation filter and is mostly
trapped in the corner of the baffle as shown. Periodically the
sedimentation box will need emptying and water may usually be
disposed down a foul drain and the solid particles in a waste bin. The
frequency on emptying the sedimentation box will vary depending on
the usage of the mains water rinse gun and the water flow directed to
the window washer. As both of these use mains water and are operator
dependent so is the frequency of water and solid disposal.
The sedimentation box is more difficult to clean if you allow too much
media to build up at the bottom of the box. Water volume is also
reduced if too much media builds up and this results in less efficient
settling of media prior to draining. Gravity settling is more efficient with
larger, heavy media so it’s difficult to inform you of exactly how often the
sedimentation box should be cleaned. Simple monitor this for the first
month and clean the box when you note 26mm (1 inch) of media/debris
build up at the bottom of the box.
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B Close Loop Rinse

This system consists of the sedimentation box as standard but have

several options.

An electrically operated solenoid valve which only allows water to drain

via the overflow after the blasting operation ceases. The time delay is
adjustable but usually 1 – 2 minutes depending on course or finer
abrasives used. The purpose of the delay is to allow the abrasives to
settle (with finer abrasives the delay should be longer than with coarser
abrasives) in the machine hopper and following this the valve opens
and allows over filling of water to exit via the overflow tube to the
sedimentation filter.

Different media types and sizes will settle at different rates therefore the
delay timer inside the electrical panel may need to be re-set to function
properly for your particular media. The goal is to carry out broken down
media and scum or oil while leaving good media in the blast hopper. To
optimize this balance, you will have to keep an eye on the filter paper
and what is being deposited on it via the pinch valve. Timing
adjustments might be necessary.

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 Adjusting the timer.

There are two setting dials that can be adjusted using a small flat screw
driver. The top setting sets the timing range. You will note that setting
this at “10” means that the second dial below it 1 – 10 is then 1 -10
seconds. Setting the upper dial at 100 then means that the middle dial 1
-10 adjusts from 1 – 100 seconds. So setting it at 5 would mean that the
timing is 50 seconds if the upper dial was set at 100. The table below is
a starting point for media mesh sizes. It’s only a starting point as further
adjustments may be necessary. Once you have set the two dials, step
on the footswitch to blast and then go to the back of the machine to
check to see if the pinch valve opens as you expected.

Media Set upper Set lower Timing

mesh Size dial at dial at result
60 10 2 20
seconds
100 10 3 30
seconds
150 10 5 50
seconds
200 10 7 70
seconds
325 10 9 90
seconds

Caution
With finer media and longer timing cycles you run the risk of the pinch
valve never opening to drain the rinse water in the cabinet back through
the closed loop system. This happens if the operator removes the
blasted part and then reloads a part and begins blasting before the
timer has timed out and opened the pinch valve.

Example: The machine is charged with 325 mesh glass bead, therefore
the timer is set to open the pinch valve and drain the rinse water back
to closed loop rinse system in 90 seconds.

Andy is blasting wire EDM parts that take him three minutes each to
blast. When he finishes blasting, he thoroughly rinses the part inside
the cabinet. The timer started its time cycle the moment Andy ceased
blasting. The timer is now counting down from 90 seconds to zero and
then it will open the pinch valve and drain the water he added during
part rinsing back to the tank on the closed loop system. This water will
replenish the water that the system relies on.
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 However, Andy is back to blasting another part in 60 seconds. So, the
time cycle was never completed and the pinch never opened to drain
the excess water back to the tank. Andy continues to blast parts in this
manner the hopper level will continue to rise and the closed loop rinse
tank will eventually run out of water. You must allow enough time for the
timer to fully time out and open the pinch valve. Adjust accordingly.

It would be expected therefore that this system would differentiate

better with fine broken down abrasive (which should be discarded
anyway) and good re-usable abrasive. Therefore water exiting the
overflow will be of higher quality or less contaminated. The closed loop
system has a paper filter and carrier supplied and due to the water
being less contaminated the debris exiting is collected mainly on the
paper roll. The paper roll needs to be pulled through manually when it
becomes over contaminated. A pneumatic pump is fitted to the base of
the sedimentation filter which supplies relatively clean water to the rinse
gun. Therefore the only overfilling occurring with use is the window
wiper which is usually consuming 5 litres of mains water/hour and
therefore allowing hours of blasting before the sedimentation filter
needs emptying.

The closed loop system can be retrofitted to a machine and costs

details etc are available through your representative/distributor or the
manufacturer.

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 SECTION 3
THE BLAST GUN

The blast gun fitted to the Aquablast is a polyurethane moulded unit designed
to resist wear due to abrasive and water running through it. The blast gun
consists of 5 components as shown in the exploded diagram below.

1 Air jet (hardened steel)

2 Grub screw
3 Polyurethane gun body
4 Nozzle
5 Nozzle retaining ring

All the above parts will wear in time and require replacement, however the
first component to wear is the hardened steel air jet. This is located or held in
the correct position using the grub screw shown. Rotation of the air jet
periodically will extend the life of this, examination is quite easy when the
nozzle is removed. The same principle of rotation will also increase the life of
the nozzle.

IMPORTANT – PLEASE OBSERVE THE POSITION OF THE AIRJET

WITHIN THE GUN BODY, WHERE THE TIP OF THE AIRJET IS FLUSH
WITH THE NOZZLE INLET. See diagram below.

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3.1 NOZZLES & AIRJETS

There are two main nozzle sizes offered with the 915 blast machine, 12mm &
14mm, and with each nozzle is a corresponding airjet. The larger air jet will
consume more compressed air. Consumption and jet sizes are detailed in
the chart below. In addition the machine is fitted as standard with a silicone
carbide nozzle, if with aluminium oxide the wear of this nozzle is excessive a
boron carbide replacement is available with a much greater life for a marginal
increase in the cost.

Free Air Consumption For Aquablast Gun

Air Jet No. Size (mm) Nozzle Size Air Consumed 30-50psi

HF3 5mm 12mm 24 - 34 cfm

HF4 6mm 14mm 40 - 60 cfm

NOTE The above nozzle and air jet combination are the standard we supply. Machines are fitted
with standard silicone carbide nozzles, boron carbide are available if required for use with
aluminium oxide.

GUIDE TO SIZING COMPRESSORS

In good condition, compressors generally produce 3 cfm (FAD) per horse

power of the electric motor. Therefore a 5 hp motor can produce 15 cfm
(FAD) of compressed air. However if a new compressor is required the cfm
should be double that required by the Aquablast, gun & air jet combination for
longevity and duty cycle.

N.B. On making air connections to the machine all hoses etc should be
checked for air leaks as even a small air leak can consume 3 or 4 cfm.

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 SECTION 4

MEDIA CONCENTRATION MONITOR

IF FITTED – OPTIONAL EXTRA
(OPTION 30 ON PRICE LIST)

(A)

(B)

A proportion of the media flow from the pump to the blast gun is fed to a
concentration monitor that is mounted outside the cabinet.

The Media Monitor is supplied with a single automatic sleeve valve (B) and a
rigid plastic tube (A).

With the blast pump running, press the button mounted on the machine leg
continuously and auto valve (B) opens. Slurry will immediately flow through
the tube, entering FROM THE BOTTOM and returning into the machine AT
THE TOP.

Release the button and the valve will close, shutting off the flow. Allow the
media to settle. The level of media in the tube will be a percentage of the
complete tube.

The condition of the media is easily visible in the plastic tube.

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 SECTION 5

PORTABLE WET CYCLONE

IF FITTED – OPTIONAL EXTRA
(OPTION 32 ON PRICE LIST)

This is used to extract the majority of media from the water before the sump
is emptied via the dump valve.

The cyclone is mounted on a separate frame which sits inside the blast
chamber when required.

To use it please carry out the following:

(a) Open the side door and place a bucket under the cyclone outlet
under the stand.

(b) Unscrew the nut on the blast gun and remove the gun nozzle.
(c) Fit the gun onto the nozzle of the cyclone inlet and tighten the
retention nut which is on the cyclone.

(d) Close the door and depress the foot pedal which normally
operates the blast gun.

(e) When the gun starts turn the air pressure regulator immediately to
‘0’ bar

The cyclone will now separate media from water and fines. The
media and some water is dumped into the bucket and the majority
of water comes out of the top outlet, back into the sump.

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 (f) The water in the bucket will overflow but that doesn't matter.
Whilst the cyclone is working you can also operate the rinse gun
washing down media off the walls so it falls into the sump.

(g) Leave the cyclone working for about 5 minutes and then switch
the blast gun off using the foot pedal.

(h) Open the door to disconnect the gun from the cyclone and refit
the nozzle and nut immediately. Gently tilt the bucket to pour out
the surplus water and you are left with the media in the base of
the bucket.

(i) Open the door and remove the cyclone and frame from the blast
chamber.

(j) The sump can now be emptied by opening the large dump valve
at the bottom of the sump as most of the contents within the sump
will be water as abrasive should be in the bucket.

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 SECTION 6
SERVICING INTERVALS – ASSUMING DAILY USE

Daily: Check water level and contamination, replenish with fresh water if
required using the water drain off valve (no. 11 on general
arrangement)

Note: Make sure a detergent or rust inhibitor is replenished and

maintained to the correct dosage if blasting and cleaning ferrous
items.

CHECKING THE PERCENTAGE OF ABRASIVE TO WATER

To check this is quite simple.

1 Turn off air supply or turn regulator on machine to zero

2 Depress foot pedal and operate blast gun for 10-15 seconds
3 Fill a straight walled container (A laboratory beaker is best. 100 ml
works well. Beakers are readily available, plastic works fine. If using a
beaker fill to 100% and then the settled media is a direct reading of
percentage) with the slurry exiting the blast gun to say 50% full
4 Allow the abrasive to settle to the bottom of the container, a 10%
abrasive to water is the desired level

Weekly

1 Check condition of abrasive and replace if required. The best indication

of broken down media is that your blast process has slowed down due
to the broken down media. After you have operated the machine for
some time you will get a feel for how long the media lasts under your
particular blast parameters.

2 To remove abrasive, connect a hose to the lower drain ball valve and
drain to waste. An air agitator is fitted to the base of the hopper to
create a slurry without the need to run the pump. Do not run the pump
dry otherwise damage will occur. Before opening the main drain valve
at the bottom of the hopper open the manual valve just above the main
drain valve. This introduced air will agitate the contents of the hopper
into a slurry for ease of draining when you open the lower main drain
valve.

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 CAUTION: BE ADVISED THAT THIS IS A SLURRY WITH A HEAVY
CONCENTRATION OF MEDIA. THIS MEDIA MUST BE SEPARTED
FROM THE WATER PRIOR TO DISPOSING INTO YOUR FACLITY
DRAIN. The next paragraph will advise you on how to manually remove
most of the media.
Alternatively, drain the water from the solution and dispose of the
abrasive manually. To do this shut off the pump and allow all the media
to settle for 15 minutes. Connect a hose to the drain port above the
main, lower hopper drain. Once the hose is connected, open the ball
valve and drain off the water. This will be mostly water due to the media
settling out below this valve. Once the water is drained off, remove the
hopper grating and dig out the media manually. Flush the entire
machine with fresh water. Be sure to wash down the ceiling, walls and
door. Close valve and recharge with abrasive, the abrasive level should
be below the water drain approximately 15 – 20 litres of volume of
abrasive will be sufficient for a full re-charge.

3 Check window glass and replace with new supplied by Vixen. Do not
use ordinary glass in this machine, the glass fitted is laminated safety
glass and ground on the edges to prevent damage to the sealing
rubber.

4 Check window wipers. Replace if ripped or if the window is not properly

cleaned after a stroke of the wiper.

5 Check blast gun hoses for wear. It’s difficult to know when to replace a
hose because it’s tough to observe mush down in the hopper. The best
time to look for leaks and wear is when you drain off just the water in
the hopper. Hose leaks tend to allow abrasive to build up in a particular
area that may be too much to get up into suspension. Look for piled
media and also for shiny spots on the hopper. This would indicate a
“blasting” effect due to the leak.

6 Check for debris in blast media (i.e. nuts, bolts, large objects which
could damage the pump)

7 Clean vent deflector from abrasive inside machine

8 Check door seal and replace if necessary, Note, the door seal has
silicone between the steel and push on bead

9 Check rubber lining of cabinet

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Aquablast (Closed Loop) Weekly Maintenance

The Aquablast’s filtration system must be maintained on a weekly basis to maintain the
waters cleanliness levels.
Firstly the sedimentation tank should be emptied, cleaned and re-filled with clean water.
The filter roll should also be monitored on a regular basis and pulled out to provide a good
clean filter surface.
Secondly the inline filter must be inspected. If the filter becomes blocked it can result in
pump damage. This can be inspected through the clear bowl, and changed if required.
To change the filter, follow the instructions below.

1. Filter located towards the back 2. Emergency stop the machine.

of the machine.

3. Release the pressure in the line 4. Unscrew the plastic bowl. Note:
through the rinse gun inside the put something below to catch
cabinet. spills.

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 5. Pour excess water into the
6. Remove filter insert and
sedimentation tank.
replace with a new filter. Dispose
of old filter.

7. Replace ‘o’ ring if worn.

8. Screw filter bowl back onto
housing. Note: make sure the ‘o’
ring is in place.

9. Release the emergency stop 10. Test the rinse gun and purge
button by rotating clockwise, air from the system.
followed by the reset button.

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Monthly

Check rubber pad bonded to base of hopper, this prevents internal wear of
the hopper due to media agitation from the agitation nozzle fed from the
pump. The rubber is glued using a 3m adhesive (Evostik type) for bonding
rubber to metal. The edges where it does not meet fully are then in filled with
silicone seal.

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 SECTION 7

7.1 BLAST MEDIA

Obviously the types of blast media suitable for the wetblast process must be
non corrosive, the most common media used for wetblasting are glass beads
and aluminium oxide (Vixosheen & Vixograin Virgin) it is important that Virgin
Aluminium Oxide is only used on re-claimed material can contain metallic
particles which again can corrode.

Other media used would be stainless steel shot ceramic beads, glass grit and
even plastic.

For further information please consult the manufacturers.

7.2 RUST INHIBITORS

It is important when blasting mild steel or cast iron components that a rust
inhibitor or detergent is added to the water solution, this prevents immediate
corrosion after the parts are blast cleaned. In addition a closed loop rinse is
preferable which operates using filtered water in the sedimentation box which
will contain a rust inhibitor that is pumped to the rinse gun (No 5 on general
arrangement) as opposed to a mains water connection as normal.

7.3 DEGREASING

Wet blasting allows for oily or greasy components to be blasted without the
need to be grease/oil free and dry as with dry blasting machines. The grease
removed is assisted by adding a non-caustic detergent (usually a liquid) to
the water solution, these detergents (available from Vixen) contain also a rust
inhibitor as above.

Most degreasing detergents operate better using a warm solution. It is

advisable that the electric heater has been switched on if fitted. The pre-set
temperature (with the heater thermostat) is normally 40°C, temperatures
above this cause high degrees of vapour and restrict operator visibility.

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 SECTION 8

PUMP DISMANTLING FOR SERVICE & INSPECTION

The Aquablast pump is a moulded polyurethane unit which is obviously non

corrosive and resistant to abrasive with the media slurry. The pump unit
when removed can be easily inspected in the following manner.

A Fig 1 shows the pump removed from the Aquablast, the first piece to
inspect before the removal is the quick release coupling must be un-
coupled shown at A. This should be checked for blockages and can be
removed by opening of the clips. Any debris trapped inside should be
removed and the unit inspected for wear. If worn replace, as this item
uses water from the pump delivery outlet and excessive wear in the
quick release coupling will result in a lower nozzle pressure & poor
performance.

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B First stop in dismantling the pump is to remove the four retaining bolts
which clamp the two piece pump body together. Ensure that if stainless
shimms are fitted between the clamps these are replaced at the correct
side. The shimms if fitted prevent the impeller catching the pump body,
it is imperative therefore that the shimms are refitted to the correct face.

B.1 The impeller consists of a stainless steel housing with a polyurethane

outer skin with 4 impeller blades. This will wear in due course and will
need replacing when the impeller blades (4 off) wear away causing low
pump performance.

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C The pump impeller is threaded and to replace simply unscrew (counter
clockwise to unscrew) from the motor shaft. In order to unscrew this
from the motor shaft simply place a screwdriver or similar through the
motor shaft, via the location hole (Fig 1.B) and the impeller can be
unscrewed. It is normal to use a soft mallet in order to break the screw
thread lock. When re-fitting ensure that the threadlock is again used
and the impeller is firmly tightened to the motor shaft once again.

TEST IMPELLOR BLADES

Test the blades to ensure sufficient
clearance. Ideal clearance is
0.5mm – 1mm

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 SECTION 9

REPLACING WINDOW GLASS

After many hours of blasting the window glass will become etched and
the visibility inside the cabinet will be impaired. The frequency of the
glass replacement will depend on the media being used i.e. glass bead or
aluminium oxide, the ricochet hitting the glass and of course the operator
using the machine. To remove the worn glass remove the inner bead
from the window seal and the glass should puss out quite easily.

Changing the glass is quite a simple procedure covered below. When

ordering your first replacement window it is advisable that the special tool
(Vixen WDR tool No 73) is purchased to make the replacement quicker.

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Finally check inside the cabinet and make sure the seal is seated correctly before
putting wiper/washer back in place.
SECTION 8
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 SECTION 10

10.1 SERVICE LINE DIAGRAM

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10.2 PARTS DIAGRAM

3 PHASE MOTOR

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