Sandcarving System Product Guide
for Discontinued 1932 & 2236 Models & the 100lb Portable Pressure Pot

Table of Contents

Safety First

Installation Requirements

Installation Instructions

Air Compressor Set-up

Cabinet Set-up

Exhaust Hose Installation

Exhaust Hose Installation Illustration

Pressure Pot Set-up

Pressure Pot Illustration & Component ID Chart

Operating Instructions

Air Compressor

Pressure Pot

Pressure Pot Settings Illustration

Blast Cabinet

Troubleshooting

Sand Shut-off Valve Assembly Illustration

Maintenance

Blasting Tips

Switch Wiring – All Models

Safety First

General

1. Before removing the Sandcarving System from the shipping pallet check the blast cabinet for any external damage that may have been caused in shipping; i.e. broken glass, loose wire connections or damage to the motor.

2. If there are any external or internal damages to the cabinet that was not noted on the carrier’s bill of lading, contact Rayzist customer service immediately to process a damage claim. Secondly, keep the packaging intact. If possible take photos of damage.

3. Use care when removing the Sandcarving System from the pallet. This is safely done with two people.

4. MSDS sheets have been enclosed for your records and safe use of the consumable products.

5. Breathing dusts produced by the abrasive media, glass, crystal or other materials being blasted may be harmful to your health. To eliminate these risks, follow all procedures for setting up the equipment and always use NIOSH approved respirators when blasting, moving parts in and out of the cabinet for blasting, when removing abrasive from the cabinet, when filling the pressure pot, and when cleaning and empting dust from the dust collector. State and local requirements may vary so check with your safety products and abrasive suppliers for their recommendation. NIOSH approved respirators recommended by our abrasive supplier are as follows: 3M 6100(small), 6200(medium), 6300(large) Half Facepiece Respirator using #2071 particulate filters.

6. Rubber gloves should be worn when blasting and whenever handling the abrasive or cleaning the cabinet.  A pair of  rubber gloves are supplied with the cabinet.  Additional gloves that are suitable for use can be purchased at your local hardware store.

7. Protective eye goggles should be worn whenever handling the abrasive or cleaning the cabinet.

8. The cabinet viewing window consists of two 12” x 24” panes of glass. The outer glass pane is a double laminate safety glass, and the inner a single strength glass pane.

Electrical

1. Make sure electrical outlet is grounded and is connected to the proper amperage circuit breaker.

2. Unplug power when doing repairs, maintenance, or replacing lamps.

Pressure Pot

1. Do not use or apply pressures higher than 100psi to the pressure pot.

2. Never do maintenance or fill pressure pot while under pressure. See instructions on page 10, Depressurizing the Pressure Pot for more information. DO NOT attempt to open the top handle until all air has been bled off to avoid serous injury.

3. The Rayzist pressure Pot is designed for use with the Rayzist sandcarving cabinet. Utilization of the pressure pot to blast outside of the cabinet should not be done without following the proper safety practices.  To obtain information on safety equipment and safe practices for outside blasting contact Clemco Industries at 636 239-0300. 

Dust Collector

1. Wear personal protective equipment such as NIOSH approved respirator, eye goggles, and gloves when maintaining and emptying dust from the dust collector.

2. Installation of vent ducting on exhaust manifold will reduce air exhaust noise and is required to evacuate any harmful dust that inadvertently bypasses the dust collector bags.  See page 6 for instructions.

Installation Requirements

Electrical:

(Grounded) 110 Volt / 60Hz 15AMP circuit breaker.

Tools Needed:

• Phillips screwdriver (or automatic screw gun) to remove bracing screws from pallet.

• Crescent wench or open end wrench – 7/16”, 7/8”, 3/4”

• 3mm Allen wrench (provided)

• Box knife

• Teflon tape (recommended) for all male NPT or airline fittings.

Compressed Air:

Compressed air is required.

Required CFM (Cubic Feet per Minute) 6.0 – 8.0

Average operating pressure @ 35psi = 5.46 CFM

For moderate use Rayzist recommends:

Grainger’s Model: # 4B227

5 horsepower, High Performance Cast Iron Air Compressor

Free Air CFM @ 90 PSI: 5.7

Free Air CFM @ 135 PSI: 4.9

Volts 60 Hz: 115/230

Amps: 15/7.5

Max Pressure (psi): 135Tank Capacity (Gal): 20H

See: www.grainger.com or call 800 225 5994

Recommended Compressor Accessories:

1. In-line water separator at compressor; this is highly recommended for humid climates (for use with 4B227 compressor).

Required Compressor Accessories:

19. Compressor Oil (1): Grainger’s model #4ZF21 

20. Air and Multi-purpose Hose, ¼” NPT (1): Grainger’s model #3JT65

21. Male ¼” NPT (industrial standard) Sleeve Coupler (1): Grainger’s model #4X397                

22. Female ¼” NPT (industrial standard) Sleeve Coupler (1): Grainger’s model #4X396                                 

23. Female ¼” NPT (industrial standard) Plug (1): Grainger’s model #2X170
     

24. 60 CFM Air / Water separator with 1/4"inlet/outlet (1): Grainger’s model #4Z034

25. Elbow, ¼”  NPT 90 Degree Angle (2): Grainger’s model # 6MN80 (pack of 10)

26. Nipple, ¼” Close (1): Grainger’s model # 6MN65 (pack of 10)

Installation Instructions

Air Compressor Set-up

1. Set up the air compressor according to the manufactures instructions.

2. Most air compressors come with an exit air pressure regulator.  If your compressor did not come with a regulator you will need to purchase one.

3. A water separator (X) should be installed in line with the air pressure regulator.  Commonly this is done with parts (Y) and (Z).

4. An NTP Sleeve Connector (U) should be connected to the end of your water separator/air pressure regulator set up.

5. A standard air hose (T) with an NTP plug (W) at one end and a NTP Sleeve Connector (V) at the other should be use to connect the air compressor to the pressure pot.

Cabinet Set-up

1. Review the enclosed System Set-up Video.

2. After removing wrapping around the Sandcarving System, remove Pressure Pot box.

3. Remove (Front & Rear) bracing on pallet with Philips screwdriver or screw-gun.

4. Remove four (4) nuts and bolts using the 7/16” open end and Crescent wrench.

5. Locate small box containing the wheels, located inside cabinet.

6. Use care when removing the Sandcarving System, slide one-side of the system forward to the edge of the pallet and install the first wheel, be sure the wheel is tight before moving on to the next. Repeat, until 4 wheels are installed. THIS IS SAFELY DONE WITH TWO PEOPLE.

7. Install the two (2) enclosed 90 watt wide-flood Halogen Lamps into the sockets; use caution not to over tighten. The lamp placement is pre-set however they can be adjusted easily to your preference. NEVER install, move or adjust the lamp while the power is on.  This should be done when the cabinet is unplugged.

8. Plug cabinet into a grounded 110 volt electrical outlet with 15 amp circuit breaker.
    

9. Turn on power-switch to test proper function of motor and lights.

Exhaust Hose Installation

There are two suggested methods for installing an exhaust hose, one is through the wall and the other is through the roof. We recommend flexible 3” air duct Grainger’s model #4XX53.

Exhaust Hose Installation Illustration

Pressure Pot Set-up

1. Un-box Pressure Pot and remove individual items.

2. Locate pressure regulator assembly (A) and loosen bail on the attached quick-clamp connector (H) with the provided Allen wrench.

3. Slide the connector and Pressure regulator assembly onto the air manifold (I) and attach to the Pressure Pot. Tighten quick-clamp connector.

Note: Do not adjust quick-clamp while pressure pot is pressurized.

  Pressure Pot Illustration & Component ID Chart
 

4. Thread the sandblast hose into the end of the sand shut-off valve (E) and tighten securely. Do not over tighten, you may strip the threads.

5. The foot pedal (F) has two quick-connect fittings that easily snap onto their corresponding connections. The BLUE hose connects to the fitting on the pressure regulator assembly (A) and the RED hose connects to the fitting on the sand shut-off valve assembly (E).

6. Place the end of the sandblast hose inside the blasting cabinet.

Note: There are right and left hole ports for right and left hand operation. The opposite hole port is an air-vent; do not block.

7. Open the top of the Pressure Pot by turning the handle counter clockwise, place the abrasive sift ring on the top of the pressure pot. Sift the 50lb. bag(s) of 150 grit Aluminum Oxide into the Pressure Pot.

Note: Do not fill the Pressure Pot with more than 100 lbs. of Aluminum Oxide or exceed the level of the pressure regulator assembly (A).

8. After the abrasive has been sifted, remove the sifting ring, pull the handle up and turn clockwise until it stops and the handle stays in the up position.

Operating Instructions

Air Compressor

1. The air compressor should be set up with a water trap, exit air pressure regulator, and air hose with quick disconnect fittings.
2. Most air compressors have an adjustment switch to set when  the compressor switches on and off.  Set the “on” pressure to 85 psi and the off pressure to 10 psi under the maximum allowable pressure from the manufacturer.
3. The sand shut-off valve assembly (E) requires at least 80 psi of air to shut off the flow of abrasive and air; therefore, set the compressor exit air regulator at about 90 psi.

Pressure Pot

1. Insert blasting hose into cabinet. It is important to keep the blasting hose straight for the first 12” on the discharge side of the sand shut-off valve assembly (E) this will prevent wear and prolong the life of the hose.
2. Make sure the Pressure Pot top is closed by pulling up the handle and twisting to the right until it stops and the handle stays in the UP position.
3. Before connecting hose from the compressor to the pot, make sure the air inlet valve (C) is in the OFF position (horizontal).
4. Connect the compressor hose to the Pressure Pot inlet valve (C)
5. Turn on the compressor.
6. Before opening the air inlet valve (C) be sure the compressor has built up at least 85 psi of pressure.
7. Open the air inlet valve (C) wide open (pointing down).

Note: When there is not 80 psi (or above) of free air pressure, (or in some cases, as soon as you open the air inlet valve) abrasive and air will start flowing out of the blasting hose.  If this occurs, depress and release pedal to stop.

8. The pressure regulator (A) sets the blasting pressure. Standard blast pressure for crystal, glass, and stone is approximately 25-35 psi.
9. Unlock the pressure regulator knob (A) by pulling upwards.  Twist clockwise to increase blast pressure or counter clockwise to decrease blast pressure.  Set regulator to desired pressure.
10. You are now ready to sandcarve your items.

Pressure Pot Settings

The Pressure Pot has two adjustment ball valves that can regulate abrasive/air flow mixture. The standard settings for the pressure pot should be made as follows: (adjustments will need to be made as wear occurs to blasting hose and nozzle). 

Pressure Pot Settings Illustration

1. Set abrasive flow valve (D) at approximate half way open or approximately 45° angle.
2. Set air flow valve (B) approximately half way open or at 45° angle.

Note: When the ball valve handle is parallel to the valve or pluming the valve is wide open. When a ball valve handle is perpendicular to the valve, it is completely closed.

3. Initially when first stepping on the pedal, you may experience a thick flow of media, or as you are blasting the flow of abrasive may pulsate with a thick flow of media; this is a common occurrence when the sand flow valve (D) is open too wide.  

Note: Sand flow valve (D) usually does not require adjustments unless there are drastic pressure changes, or larger nozzle orifices are used. 

4. If there is too much air coming out of the blasting hose (the stream of abrasive is too thin), close the air flow valve (B) slightly. If there is too much abrasive coming out of the blasting hose (abrasive flow is too thick), close slightly.

Note: Air flow valve (B) adjusts how much air pushes the abrasive through the blast hose. Less air flow = more abrasive.  More air flow = less abrasive.

Depressurizing the Pressure Pot

1. To depressurize Pressure Pot, first close air inlet valve (C), then step on foot pedal until sand and air stops flowing and the pressure gauge reads “0”.
2. DO NOT attempt to open the top handle until all air has been bled off.

Note: Do not depressurize with the pressure regulator knob (A) or water separator drain valve (G), abrasive may back-up into the pressure regulator.

Blast Cabinet

1. Turn on blasting cabinet power switch, the dust collector and lights should both be operating.
2. Use (provided) rubber gloves. Rubber or latex safety gloves can be purchased from a local hardware store.
3. Place item to be etched inside cabinet. Hold blast hose in hand (like a writing tool).
4. By pressing on the foot pedal (F) the air/abrasive flow starts, and by letting off the foot pedal the air/abrasive stops.
5. Depress pedal, holding blasting hose 3” - 4” away from item, use slow sweeping motions across image area to be etched.

Recycling Abrasive

1. Breathing dust from the cabinet may be harmful. NIOSH approved respirator, eye goggles, and gloves are supplied for your personal safety. Wear personal protective equipment when removing abrasive from the cabinet and when filling the pressure pot.
2. Depressurize the pressure pot according to the instructions listed under Depressurizing the Pressure Pot.
3. Make sure that the Dust collector is turned on.
4. Place a 5 gallon bucket below the trap door on the blast cabinet.  Open the door slowly and fill the bucket according to your lifting ability.  A 5 gallon bucket half full weighs approximately 50 lbs, one quarter full weighs approximately 25 lbs.  This weight will need to be lifted chest height to fill the pressure pot.
5. Pour the abrasive into your pressure pot thru a sifting ring.

Troubleshooting

1. Sand and air continues to flow at full force when you remove your foot from the pedal.

Solution:

1. The diaphragm gasket has a hole worn in it and needs replacement.
2. OR, Check output pressure of your air compressor; output pressure needs to be greater than 80 psi.
3. OR, The foot pedal (F) actuator could be stuck (not likely).

To replace gasket, DEPRESSURIZE the pressure pot according to the instructions listed under Depressurizing the Pressure Pot, and remove the four wing bolts holding the upper and lower sand shut-off valve.

Note: It only takes a small hole in the gasket to cause it to fail.

Sand Shut-off Valve Assembly Illustration

2. A small amount of abrasive and air continues to flow when you remove your foot from the pedal.

Solution:

This problem occurs after a long period of time when the sand shut-off valve assembly (E) develops a groove across the plastic web.  Replace.

3. The blasting hose is “spitting” abrasive, or looses abrasive flow a few moments after stepping on the pedal.

Solution:

1. Pressure Pot is getting low on abrasive.  Refill.
2. OR, Abrasive has become wet (fine to powdery abrasive will tend to clump together and will not flow smoothly) from the pot.  Replace with dry abrasive and empty water traps.
3. OR, There is a clog in the line. Remove the carbide nozzle and check to make sure nothing is stuck in the opening. With the nozzle off, open valves (B) and (D) to full position and step on the foot pedal and see if there is a constant flow of abrasive and air.  Return valves to 45° or the position you had them set in and attach carbide nozzle.

4. Air is coming out of the blasting hose but No Abrasive.

Solution:

1. There may be a clog in valve (D), preventing abrasive from flowing.  DEPRESSURIZE tank and loosen large union nut (J). Inspect the sand shut-off valve. (E), free any blockage, and possibly drain and sift abrasive.

5. No Abrasive or Air is coming out of the blasting hose.

Solution:

1. Foot pedal (F) is not working. Replace.
2. OR, there is a blockage in the blast hose (K).

·        With the hose in the cabinet remove nozzle; free any clogged substance in nozzle.

·        With nozzle off, and hose in the cabinet step on pedal to free any debris from hose.

·        Shut off sand flow valve (D), and open Air Flow valve (B) full wide and step on pedal until blast-hose is free of blockage.

·        Depressurize tank and remove lower sand flow valve (D) to free any blockage.

6. Excessive dust in blasting cabinet, loss of visibility

Solution:

1. Usually caused by worn out abrasive. Replace abrasive; do not mix new abrasive in with old.
2. OR, The dust collector bags are full. Wearing a NIOSH approved respirator, eye goggles, gloves, and with the system unplugged, shake dust collector bags (freeing fine dust particles trapped in the fibers of the bag). Empty dust collector trap.
3. OR, the blast hose holes in the cabinet are blocked. The holes provide the air flow to evacuate the dust.
4. OR, Inner pane of single strength glass has become frosted over a period of time and needs to be replaced.

Maintenance

Never service a Pressure Pot while under pressure. See instructions on page 10, Depressurizing the Pressure Pot for more information.  Before maintaining lamps or dust collector make sure blast cabinet is unplugged to avoid serous injury.

Maintenance to your system is predicated on the usage of your basting system, higher then recommended blasting pressures of 25-30psi, or blasting abrasive above 150 grit will result in inconsistent or premature wear items.

Daily Maintenance

1. Air compressor

• Drain water from compressor and water traps.

2. Pressure Pot

• Drain water from water trap.

3. Dust collector unit

• Daily or after eight hours of use: Wearing a NIOSH approved respirator, eye goggles, gloves, and with the system unplugged, shake the dust collector bags vigorously to prevent dust build-up from forming inside the bag.
• Empty dust collector trap.

Periodic Maintenance

1. Abrasive

• Life expectancy: (rated in recycles) approximately 8-10 recycles.
• Always sift through a sifting ring.
• Replace when:
  1. Blasting is taking considerably longer.
  2. Abrasive becomes excessively dusty.

2. Cabinet Viewing Window

• Consists of two 12” x 24” panes of glass, outer double safety laminate (replacement not required), the inner single strength glass will get frosted over time which will impair visibility.
• To replace: loosen the ten window bracket screws, and carefully slide both panes of glass out. Use caution as edges of the glass can be very sharp.
• Replace (inner) single strength glass pane. Once the glass is centered in the window brackets, retighten screws until snug. 

Note: 12” x 24” single strength window glass can be purchased from a local glass retailer.

4. Dust Collector Unit

• Life expectancy of dust collector bags: approximately 300 hrs.

5. Diaphram Gasket

• Life expectancy: is approximately 40 hrs. Replace when gasket develops a hole and will no longer shut off the flow of abrasive and air.

6. Blasting Hose

• (Standard Duty Blast Hose) Life expectancy: approximately 80 hrs.
• (Heavy Duty Blast Hose) Life expectancy: approximately 130 hrs.
• Pinch the blasting hose 3” - 4” from the Sand Shut-off valve (E), if the hose collapses in-between your fingers, the hose will blow out soon. Replace hose before it blows out.
• Keep the blasting hose straight for the first 12” on the discharge side of the Sand Shut-off valve (E) to prolong the wear of the hose. The hose will ware more rapidly on sharp bends or kinks.

Note: Use Heavy Duty Blast Hose when blasting pressure is above 35 psi. or when blasting for prolong periods of time.

7. Sand Shut-off Valve

• Check ware on inside of the valve each time you replace the diaphram gasket. If a groove has developed across the web and air and abrasive leak out the nozzle when the foot pedal is not depressed, replace the sand shut-off valve (E).

8. Nozzle

• Life expectancy: approximately 100 hrs.
• Replace when the nozzle orifice exceeds 1/8”. A large orifice will cause damage to the mask and may blow off small pieces of detail.

9. Weather Strip Seal

• After a long period of time the weather strip seal on the dust collector doors and main cabinet doors may loose their effectiveness and need replacement.

Keep spare parts on-hand

Blasting Tips

• Equip Pressure Pot with heavy-duty blast hose and foot pedal when blasting pressure is above 35 psi. or when blasting for prolong periods of time.

• Average blasting pressure: 30-35 psi.

• Average blasting distance: 4” - 6” away from the item.

• Protect areas of the exposed surface around the mask with blasting tape

• Blast angle is always 90°. Blasting on an angle prematurely or in the wrong areas (such as text) can cause blowouts.

• "Trace" the design to blast away the membrane first. Then go back, continuing to use small circular motions to carve the item. Always keep the nozzle moving.

• A general rule in sandcarving is to not blast deeper then the width of a line. Blasting deeper than the width of a line, text, or graphic will cause a V shape cut and become difficult to read or cause the image to appear shadowed, or cause  blow-offs with the centers of the letters “a”, “e”, etc.

• When blasting you will see the photo resist turn from blue to a darker brown. Use caution (especially on 3-mil film). Always keep the nozzle moving. Once the photo resist begins to turn dark brown granules of abrasive will no longer be resisted by the surface of the mask. This may cause small “chipping” into the glass surface causing visible blast though.  Pressure for 3 mil should not exceed 30 psi.

Switch Wiring – All Models