Blastrac BDC-955 User manual

OPERATING MANUAL BDC-955
VERSION 2.1

2
EC DECLARATION OF CONFORMITY
in accordance with Appendix II sub A of Directive 2006/42/EC
BLASTRAC B.V.
Utrechthaven 12
NL - 3433 PN NIEUWEGEIN
Tel: [phone]
Fax: [phone]
[e-mail]
The Netherlands
We declare under our sole responsibility that the machine as described below conforms with the Health and
Safety requirements of the European Directive for machine Safety.
In case of changes to the machine without our written authorization this declaration loses its validity.
Model: Blastrac BDC-955-0000 Serial number: xxxxxxx
1. satisfies the conditions set out in the Machine Directive (Directive 2006/42/EC); Low voltage directive
(2006/95/EC, as last amended; EMC directive 2004/108/EC, as last amended)
2. satisfies the following harmonized standards:
NEN-EN 292-1, NEN-EN 60335-1, NEN-EN 60335-2-69, NEN-EN 55014, NEN-EN 55014-2 and NEN-EN
61000-3-2
Nieuwegein 28-05-2009

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Table of contents
EC Declaration of Conformity 02
1. Introduction 04
2. Machine description 04
Application & functioning
3. Safety 08
Safety precautions - general
Safety precautions - with regard to transport
Safety regulations
4. Before operation 10
Checkpoints of electrical safety
5. Operation 10
Switch on the machine
Work with the machine
Emptying the dust bin
Interrupting work
Exchanging the dust bag
6. Maintenance 12
Filter replacement
Pulse system
Water separator
Compressor
7. Technical data 20
Contact 21

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1. Introduction
It is important that all persons who are working or maintaining this machine read the manual carefully and
understand it fully.
Keep this manual near to the machine, so it can always be consulted.
Only authorized and trained personnel may operate this machine.
2. Machine description
The Blastrac dust collector BDC-955 can only be used for dry cleaning.
It should only be used for removing not-inflammable dust or substances.
The BDC-955 must not be used for carcinogenic or asbestos substances.
The machine is designed for usage in conditions according to classification M (see below).
Classification acc. standard EN 60335-2-69 –Annexe AA
Type
Class
Designation
BDC-955
M
(Medium risk) for separating dust with an
exposure limit value of over 0,1 mg/m3,
depending on the volume occupied.
Dust emissions into the environment
Class
Value of performance
L
Retains at least 99,1 % of particles measuring ≥ 3 μm
M
Retains at least 99,9 % of particles measuring ≥ 3 μm
H
Class H13 HEPA filter in accordance with EN1822
The BDC-955 is available in 2 versions: 400-440 Volt 50 and 60Hz version.
Application
The BDC-955 is especially designed to be used in combination with Blastrac Blasting machines and scarifiers.
Contact Blastrac B.V. for the correct execution and combinations.

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ITEM
DESCRIPTION
1
WHEELS
2
FILTER CHAMBER
3
PULSE CHAMBER
4
CONTROL PANEL
5
WATER SEPARATOR
6
AIR PISTOL
7
PULSE SYSTEM
8
PULSE CONTROL
9
FAN UNIT
10
HOIST BEAM
11
COMPRESSOR
12
SILENCER
13
END PART
14
DISCHARGE & BAG UNIT
15
COVERS
16
HOSE ADAPTER
17
BIG BAG
FOR DETAIL OF
CONTROL PANEL, SEE
FIGURE 2.2
FIGURE 2.1 –MACHINE OVERVIEW

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FILTER CHAMBER
Contains 9 filter cartridges for the separation of dust from the airflow.
PULSE CHAMBER
Separates the filter chamber from the ‘clean air’ side and seals the filtercartridges.
CONTROL PANEL
Controls the functioning of the dustcollector and powersupply to the applications (see figure 2.2).
WATER SEPARATOR
Separation of water from the pulse system. The separator drains automatically. Optional a small bottle
(approx. 20 –30 c.c.) can be placed in the holder below the separator, in order to prevent the fluid
contaminating the floor.
AIR PISTOL
Accessory for cleaning the dustcollector.
PULSE SYSTEM
For pulse cleaning of. Increases life-time of the filtercartridges by pulse cleaning.
PULSE CONTROL
Controls the pulse valves.
FAN UNIT
Creates an airflow for a correct functioning of the combined application.
The air flow through the complete system during the application of the blast cleaning machine and the dust
collector has the following functions:
Cooling of the blast wheels
Cooling of the abrasive
Transport of the abrasive
Transport of dust through the system
Separation of dust from the re-useable abrasive
Transport of dust to the dust collector
HOIST BEAM
Single hoisting point for transport of the dustcollector.
COMPRESSOR
Feeds the pulse system with compressed air.
SILENCER
Sound damping air outlet with integrated air-flow control valve.
END PART
Cable support.

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DISCHARGE & BAG UNIT
For dust discharge and handling of the dustbags. The discharge tray has an integrated valve which enables
continuous working with the combined application.
HOSE ADAPTER
Accessory which enables connection of a 5” (130 mm.) suction hose, instead of the standard 6” (150 mm.)
hose.
BIG BAG
Captures and simplifies a hygienic transport of the processed dust. 1 dustbag is delivered with the
dustcollector. The dustbags are sold separately in sets of 50 pieces (part E06311).
Main switch
The main switch is located on the main box. It has to be switched on before operating the dust collector and the
blast cleaning machine.
Button Compressor/Fan ON/OFF
Pressing the button "ON" switches the compressor / fan on, pressing the button "OFF" switches the compressor
and the fan off.
Button Screwconveyor ON/OFF (optional)
Pressing the button "ON" switches the (optional) screw conveyor on, pressing the button "OFF" switches the
compressor and the fan off.
Control lamp Thermical failure
This lamp shines when the machine is overloaded.
Control lamp Phase incorrect
This lamp shines when there is a failure with the phases.
FIGURE 2.2 - DETAIL OF CONTROL PANEL

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Emergency shutdown switch
Red mushroom-shaped press switch onto a yellow background.Pressing this switch immediately stops the power
supply to all units of the machine, shut down switch requires re-setting after it has been used.
Connectors
Enables the connection of an application, e.g. a Blastrac blasting –or scarifying machine.
Hour counter
Shows the working time of the Dustcollector in hours. Registration of the working hours enables to follow a
correct maintenance schedule.
3. Safety
Before operating the machine, the personnel must be familiar with the safety instructions given in this manual.
Keep this manual near to the machine, so that it may always be consulted.
Safety precautions –general
It should only be used for removing not-inflammable dust or substances.
The unit should not be used near flammable gasses or substances.
The BDC-955 must not be applied for carcinogenic or asbestos substances.
Packing material, like plastic bags, should not be in reach of children’s with regard of asphyxiation
danger.
The voltage on the identification plate must comply with the power supply.
Do not use the unit when it is damaged.
Do not use damaged extension cables.
Do not pull the power supply cable over sharp edges, fold the cable or clamp it.
Never use this machine for sucking water or liquids.
Acids, acetone or solvents can damage the machine.
During a standstill of the machine, pull out the plug.
Don’t pull out the power supply cable out by the wire, but by the connector.
Use only original Blastrac parts.
The dust collector must be yearly overhauled by a skilled technician.
Safety precautions –with regard to transport
Remove the dustbag from the dust collector and close the discharge valve before it is
transported. Close the silencer valve outlet of the dust collector. The dust collector may only be
lifted by using the (single point) hoisting beam. It may by tightened by fastening straps to the
indicated points on the housing frame (see chapter 2). The weight and dimensions of the dust
collector are shown in Chapter 7 "Technical data“.
When transporting the dust collector do so in such a manner that damage due to the effects of the use
of force or incorrect loading and unloading is avoided.
Before the dust collector is removed from the hazardous zone, take precautions to prevent dust from
escaping. Always close the inlet of the dust collector with the appropriate plug

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Safety precautions –with regard to maintenance
To allow the user to carry out maintenance operations, the dust collector must be disassembled,
cleaned and inspected as far as reasonably possible, without causing hazards for the maintenance staff
or other people.
The suitable precautions include decontamination before disassembling the dust collector, adequate
filtered ventilation of the exhaust air from the room in which it is disassembled, cleaning of the
maintenance area and suitable personal protection.
The external parts of the dust collector must be decontaminated by cleaning and vacuuming methods,
de-dusted before being taken out from the hazardous zone. All parts of the dust collector must be
considered as contaminated when they are removed from the hazardous zone and appropriate actions
must be taken to prevent dust from dispersing.
When maintenance or repair procedures are carried out, all the contaminated elements that cannot be
properly cleaned, must be destroyed.
These elements must be disposed of in sealed bags according to the applicable regulations and in
accordance with the local laws governing the disposal of such material.
This procedure must also be followed when the filters have to be disposed.
Compartments that are not dust-tight must be opened with suitable tools and thoroughly cleaned.
Safety regulations
The following sticker is placed on the machine.
Meanings of these symbols are:
Ear protection is obliged
Safety glasses with lateral protection are obliged
CE-mark on this machine
Safety shoes obliged
Consult the manual before operating the machine
Personnel must tie back long hair and not wear loose clothing or jewellery including rings.
Wear gloves and dust mask during operating the machine.
Persons who are not operating the machine must not be permitted to stay in the surrounding area of
the machine.
Don’t change anything on the machine. Use always cables which are approved and safety earthed
(extend) cables. The machine is always equipped with an earthed connection, do not change this and
use always earthed cables with an earthed plug.
Connect the main power supply cable to an installation with an earth leakage circuit breaker.
Inspect and test the electrical components regularly. The electrical components have to satisfy to the
requirements which apply to these components.
Always call a skilled electrician or your distributor when you have questions about the safety of the
electrical components.
Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or
by trained persons under the guidance and supervision of a skilled electrician as well as in accordance
with the electrical engineering regulations.
Pull out the main plug during inspections and repair operations on the machine.
Never operate the machine when the surface is wet.
Never use the machine in the rain.

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4. Before operation
Before using the machine it is essential to inspect the machine.
It is not permitted to use the machine if the machine safety is not according the checkpoints below.
Checkpoints of electrical safety
Use only extension cables for extending the main cable that are sized and marked in accordance with
the overall power consumption of the machine.
Electrical cables must be rolled entirely off of the reels.
Any damage to electric cables is not permitted
Use an electrical power supply connection with earth connection.
The main switch of the machine should be put to ‘Off’ before connecting to the power supply.
5. Operation
Switch on the machine
Connect the dust hose to the machine.
Attach a dustbag in the bag lifting system and secure the opening of the bag to the discharge outlet
with the belt.
Open the valve of the discharge (handle position up)
Make sure the switches of the dust collector are in “Off” position.
Connect the dust collector to the power supply.
Switch on first the compressor motor.
Secondly switch on the fan motor.
Start working with the machine.
Work with the machine
Regular check the contents of the dust-bag. When full, proceed with ‘Exchanging the dust-bag’.
Read-out the pressure indicators on the pulse chamber regular and check for a functional pulse-
cleaning on the dust-collector.
Interrupting work
When temporarily interrupting the work (1/2 hour –1 hour), turn-off the fan-unit only. Pulse-cleaning
of the filter-system will continue and will increase the life-time of the filter-cartridges.
During a longer stand-still of the dust-collector, first switch-off the fan-unit. Let the pulse-cleaning
cycle run for +/- 5 minutes. Switch-off the compressor unit and Main-switch.
Disconnect the power-supply cable.
Prevent un-authorized persons from getting access to the dust-collector or take measurements to
prevent un-authorized working with the equipment.

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Exchanging the dustbag
The dust-bag can be replaced during working with the dust-collector by closing the valve on the discharge-
outlet. The capacity of the discharge-bin enables continuation of the working process.
Check regularly the level of the dust-bag. The periods of checking depends on the surface to be
cleaned.
When the dust-bag is full, close the valve of the discharge-outlet (valve handle horizontal).
FIGURE 5.1
Loosen the belt of the bag-inlet.
Seal the bag-inlet by means of the chords on the bag.
Slowly drop the bag on the ground by tilting the bag lifting handle up.
FIGURE 5.2
Remove the straps out of the lifting unit and replace the full bag by a new.
Lift-up and seal the bag with the belt.
Open the valve of the discharge-outlet (valve handle vertical).
Dispose the full bag. Observe the waste disposal regulations; in uncertain situation ask your next
policy level.

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6. Maintenance
Pay attention to Chapter 3 "Safety" during maintenance and repair works.
Failures due to inadequate or incorrect maintenance may generate very high repair costs and long standstill
periods of the dust collector. Regular maintenance therefore is imperative.
Operational safety and service life of the dust collector depend, among other things, on proper maintenance.
The following table shows recommendations about time, inspection and maintenance for the normal use of the
dust collector.
Operating hours/
time period
Inspection points, maintenance instructions
12 h after repairing
Check all accessible screw connections for tight seat.
Daily and prior to
starting work
Check all safety devices working adequate.
Check the function of the residual current operated device.
Check the hose connections for tightness and fixed seat.
Check the hose to the filter for damages.
Make sure that the dust bin of the filter is emptied
Check the electric connections for sediments of dirt or foreign bodies.
Check the electric motors for dirt and other contaminants.
Annually
Full overhaul and cleaning of the complete dust collector.
After 50 working hours
Change compressor oil.
After 300 working
hours, using mineral oil
Change compressor oil.
After 900 working
hours, using synthetic
oil
Change compressor oil.
The time indications are based on uninterrupted operation. When the indicated number of working hours is not
achieved during the corresponding period, the period can be extended. However a full overhaul must be
carried out at least once a year.
Due to different working conditions it can’t be foreseen how frequently inspections for wear check’s,
inspection, maintenance and repair works ought to be carried out. Prepare a suitable inspection schedule
considering your own working conditions and experience.
Our specialists will be happy to assist you with more advice.
Prior to any repair works on the dust collector and its drives, secure
the dust collector against unintentional switching-on. Put the dust
collector to its safety off position. Also make sure there is no air
pressure on the pulse system.
Follow additional operating and maintenance of OEM if included
during your service and maintenance work.

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Further is advised:
Store the cleaned and dry machine in a dry and humid free room. Protect the electrical motors from moisture,
heat, dust and shocks.
All repair work must to be done by qualified Blastrac personnel, this to guarantee a safe and reliable machine.
Any guarantee on the machine is expired when:
Non original Blastrac parts have been used
Repair work is not done by qualified Blastrac personnel
Changes, add on’s or conversions are undertaken without written permission of Blastrac BV
Filter replacement
1Switch off the dust collector and pull out the power supply.
2Loosen the top bolts of the hoisting beam (do not remove them).
3Loosen the hose on pulse-chamber.
4Loosen the bolts of the pulse-chamber at the hinge position.
5Loosen the nuts of the eye-bolts (do not remove them) and swap the eye-bolts up.
6Rotate the center-handles left & right up, to ease tilting the pulse-chamber up.
7Remove the safety (quick release) pins.
8Lift the pulse chamber up.
9Lock the pulse chamber in upward position by inserting the quick-release pins at the original position.
10 Replace the filter-cartridges.
2
3
4
6
2
7
FIGURE 6.1

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11 Follow above given procedures in reverse to restore the pulse-chamber position. Carefully and evenly
tension (in cross-direction) the bolts and nuts in order to obtain an adequate sealing.
Torque the tension devices with 26 up to 30 Nm.
12 When hose and hoisting beam are mounted back in position, start the fan-unit. Due to the vacuum in
the filter-unit the pulse-camber may slightly be pressed further in its sealing.
13 Check and re-tension the pulse-chamber when necessary.
14 Continue work with the dust-collector.
Pulse system
The Dust collector is provided with a air pulse cleaning system which increases the life of the filter
cartridges.
The system works by use of pressurized air, built up by a belt driven compressor
The air is leaded through a waterseparator to the pulse system.
Compressor
Water
separator
FIGURE 6.3
FIGURE 6.4
10
9
9
8
FIGURE 6.2

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Pressure gauge
FIGURE 6.6
The conditioned air then passes a control valve (see fig. 6.5), which regulates the systems pressure , and then
builds up pressure in the pulse tank.
Normally the pressure in the system lies between 6 and 7 bar. The safety valve mounted on the pulse tank is
activated at approximately 10 bar.
This provision is to ensure that when there is a defect in the Control valve, the pressure in the pulse tank
remains within safe limits.
The pressure in the pulse system is indicated on the pressure gauge.
It is mounted in the Filter house next to the vacuum gauge.
If the pressure of 7 bar is not reached, it is possible that either the filter of the water separator or the air filter
of the compressor is dirty.
For maintenance instructions on the waterseparator and the compressor see the applicable paragraphs.
Pulse tank
Safety valve
Control valve
FIGURE 6.5

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Level indicator
marking
Outlet ring
FIGURE 6.9
FIGURE 6.8
If inspection on the waterseparator or compressor shows no dirty filter, it is possible that either there is a
leakage in the air tubing, or the control valve is defect. In that case replace the defective parts or have it
checked by Blastrac.
When there is pressure but the pulse system does not function, there might be a problem in the electrical
system which controls the pulsing system. Check the wiring and the PLC-settings.
Advised is to take contact with Blastrac Support in order to prevent operational problems.
Water separator
Periodically check the level indicator of the waterseparator.
If there is condensate level approximately 10 mm below the level indicator marking (see figure 6.8 ) then
either press in or turn the outlet ring as shown on figure 6.9 .
FIGURE 6.7

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In case of less air flow as mentioned in the paragraph above, replace the filter of the waterseparator as
following:
Push unlocking slide down and turn filter bowl in anti-clockwise direction. Then pull filter bowl away from the
separator.
Turn the filter screw loose and replace the dirty filter by a new one as shown on figure 6.11 . Hold the new
filter element only at the lower end .
Fasten the filter screw and place the filter bowl back . Make sure the locking pin points towards the large
recess (see figure 7.10.5 ).
When fastening the filter bowl, make sure you hear a clear snap.
FIGURE 6.11
FIGURE 6.10

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Compressor
The oil level and air filter of the compressor should periodically be inspected acc. to the inspection table given
values.
Replacement or cleaning of the air filter is depending on the environment in which the Dust collector is
operating.
FIGURE 6.12
FIGURE 6.13
Air
filter
FIGURE 6.14

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The height of the oil level oil level must lay on approximately half of the oil level indicator , about 0,25 liter.
Use only oil especially mend for compressors, according specification C.T. 68 ( ISO 68 –viscosity ) .
Prior to draining-off , the compressor unit should have operating temperature.
FIGURE 6.15

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7. Technical data
BDC-955
Power consumption
5.5 kW
Electrical connection / fuel
400-440V / 50-60Hz
Air stream
(hose end)
1324 m3/hr
Dust hose connection
Ø130 - 150 mm
Total filter surface
36m2
Length
980 mm
Width
820 mm
Height
1500 mm
Weight, with cable ( / cable loose)
552 kg ( / 538 kg)
Noise level (at 1 mtr. distance)
Up to 95 dB(A)
Design and specifications are subject to change without notice by Blastrac B.V.