Blastrac 2-45DTM User manual

Original instructions
OPERATING INSTRUCTIONS 2-45DTM
VERSION .4
2
-
45D
-
UNIT
-
ROEHSLER

2
(Übersetzung des Originals. Das Original ist in englischer Sprache)
EC-KONFORMITÄTSERKLÄRUNG
in Übereinstimmung mit Appendix II sub A der Richtlinie 2006/42/EC
BLASTRAC B.V.
Utrechthaven 12
NL- 4 PN NIEUWEGEIN
Tel.: + 1 (0) 0 6018-866
Fax: + 1 (0) 0 6018-
[email protected]
Niederlande
Wir erklären in alleiniger Verantwortung, dass die unten beschriebene Maschine
mit den Gesundheits- und Sicherheits-Anforderungen der europäischen Richtlinie
der Maschinensicherheit konform ist.
Im Falle von Änderungen an der Maschine ohne unsere schriftliche Genehmigung verliert diese Erklärung ihre
Gültigkeit.
Modell: BLASTRAC 2-45D Seriennummer: ……….
1. erfüllt die in der Maschinenrichtlinie (2006/42/EG) sowie in der Niederspannungsrichtlinie
(2006/95/EG, wie zuletzt geändert) und der EMV-Richtlinie (2004/108/EG, wie zuletzt geändert)
festgelegten Bedingungen.
2. erfüllt die folgenden harmonisierten Normen:
NEN-EN 49, NEN-EN 418, NEN-EN 294 and NEN-EN 60204
Nieuwegein …………

3
Index
1. Introd ction 4
2. Machine description 4
2.1 Blast unit 4
2.2 Separator, magnetic drum and hopper 5
2. Blast wheel 6
2.4 Abrasive sealing 6
2.5 Side brush housing 7
2.6 Side shift and adapter 7
2.7 Dust collector 2-45TDC 8
2.8 Tow behind sweeper 11
3. Safety 12
4. Initial operation 19
4.1 Checkpoints: 19
4.2 Switching from ‘Drive-mode to ‘Hydro-mode’ 20
4. Connecting the blast unit with the truck 2
4.4 Start-up of the dust collector 25
5. Operation of the blast nit 26
5.1 Before blasting 26
5.2 Blasting with the 2-45DTM 26
5. Switching the machine off 27
5.4 Driving backwards 27
5.5 Adjusting the blast pattern 28
5.6 Setting the control cages 29
Operation of the d st collector 30
5.7 Procedure for replacing a filled Big Bag 0
5.8 How to replace a full BigBag 1
5.9 Blower throttle 2
5.10 Tips for working with the 2-45TDC 2
5.11 Interrupting work 2
5.12 Stopping 2
5.1 Transport
5.14 Touch screen
6. Maintenance 35
6.1 Changing the liners 7
6.2 Changing blastwheel blades, impellers & cages 8
6. Deflector maintenance 9
6.4 Side shift & adapter maintenance 40
6.5 When to change the filters? 41
6.6 Filter replacement 42
6.7 Pulse system 4
6.8 Compressor 45
6.9 Water separator 45
6.10 Belts 46
6.11 Fitting the belts 46
6.12 Tensioning the belts 46
6.1 Blower maintenance 47
6.14 Rotating valves 48
6.15 BigBag clamp 49
6.16 24V Winch and remote control 50
6.17 Shot valves and actuators 51
7. Tro bleshooting 52
8. Selection of abrasive 54
9. Technical data 55
9.1 Sound and vibration data 57
Contact

4
1. Introd ction
Before use, operators shall be provided with information, instruction and training for the use of the machine
and the substances for which it is to be used, including the safe method of removal and disposal of the
material collected. All persons who are working with or maintaining this machine must read the manual
carefully and understand it fully. In case you sell the unit, hand it on to the next owner.
Keep this manual always with the machine, to enable it to be referred to at any time.
Any other work not covered by this operating manual must not be carried out.
This machine is designed for industrial use by professionals. Only a thorized and trained personnel may
operate this machine. This machine is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge. Blastrac BV offers a course on
the use of the machine in order to make the operating and maintenance personnel familiar with all elements of
the machine.
2. Machine description
2.1 Blast nit
The Blastrac blast cleaning machine 2-45D is a downward blasting machine with a closed abrasive circuit
exclusively designed for the pre-treatment of dry, frost-free, horizontal surfaces. The bouncing impact of
metallic abrasive onto the surface to be treated thoroughly removes surface contaminants, coats of paint,
sealants and thin coatings.
A suitable filter unit must be connected to the machine in order to separate the dust from the abrasive.
A specially designed dust collection system ensures dust-free operation of the machine and clean air at the
workspace.
2.1 Blast unit
2.6 Side shift & Adapter
2.7 Dust collector
2.8
Tow
behind
sweeper
(Option)

5
2.2 Separator, magnetic dr m and hopper
The abrasive separator is mounted to the end of the recovery duct. It separates the abrasive from
contaminants and feeds the cleaned abrasive onto the magnetic drum(2). This magnetic drum functions as a
second separator for bigger particles and feeds the cleaned abrasive back to the abrasive storage hopper(7).
Two wire meshes are fitted to prevent any coarse contaminants from getting into the blast wheel. In order to
clean the wire mesh drawers, the drawers can be removed from the sides(8).
1 Separator cover
2 Magnetic drum
Deflector
4 Separator
5 Magnetic drum motor
6 Belt cover
7 Hopper
(part of separator)
8 Separator tray
9 Hose connector
1 Separator inc. hopper
2 Separator tray
Magnet drum drive
4 Dust hose connection
5 Feed spout
6 Control cage clamps
7 Abrasive sealing
8 Rebound
9 Transport castor (foldable)

6
2.3 Blast wheel
The heart of the blast cleaning machine are two blast wheels that throw the abrasive onto the surface to be
cleaned by using centrifugal force. The blast wheels are placed in a protective housing lined with replaceable
wear parts. The blast wheels are driven by two hydraulic motors.
1 Control cage
2 Impeller
Blades (set of 6)
4 Blast wheel
Around the centre of the blast wheel there is the impeller feeding dosed quantities of abrasive onto the blades
of the turning blast wheel. On top of this is the control cage, which once it is carefully set, regulates the
throwing angle of the abrasive.
2.4 Abrasive sealing
Magnetic seals are fitted to the front and the sides of the blast housing outlet and are surrounded by rubber and
brush seals. At the rear there are four skid seals sliding over the floor.
The seals are employed to seal the blasting area in a way to avoid leakage of any abrasive.
The correct height adjustment of the magnetic seals (16-20 mm) is very important for optimum functionality of
the machine. The adjustment can be carried out by means of shaft nuts at the front and rear wheels.
1Side brush housing
2Side magnet
Front magnet
4 Front brush
5 Front seal rubber
6 Side seal rubber
7 Rear brush

7
2.5 Side br sh ho sing:
The inner- and outer side brush are able to float over the treated surface. The brushes are clamped between
two guides. This assembly is pressed on the floor by two springs inside the brush housing. The floating side
brushes are kept inside the brush housing by two screws mounted at the side.
1Brush housing
2Side brush spring
Guide
4Felt seal
5Side brush inner
6Side brush outer
2.6 Side shift and adapter
The side shift and machine adapter is designed to mount a
Blastrac 2-45D blast cleaning machine on a truck. During
blasting it is possible to shift the blast head from the total left
side to the total right side, outside the reach of the wheels of the
truck. This enables blasting as close to the sides as possible.
The side shift should only be used when the machine is moving
forward or backwards, or when the blasthead is lifted off the
ground. Using the side shift in standstill position with the
blasthead on the ground could damage the oil pump.
Don’t use the equipment for any other purpose than to mount a
2-45D blast cleaning machine to a truck.
Please note that the illustrations are simplified.

8
There are 4 hydraulic connections, 1 electrical connection and 2 sleeve
bolts to connect the side shift & adapter to the front of the truck.
The 4 hydraulic rotary couplings should be cleaned before and after
each use. Use brake cleaner or something similar to do so. Use the red
protection caps after each use.
Place a bucket underneath the couplings when connecting or
disconnecting them to catch the drops of oil that may be spilled.
The electrical connection on the truck has a clamp to lock the connector
in place, always use this to prevent any water or dust entering the
connector during work.
The electrical connection on the truck also has a protective cap, always
close it during transport.
The sleeved bolts should always be tightened firmly. Use the wrench
and socket wrench to do so.
2.7 D st collector 2-45TDC
The 2-45TDC is a very powerful truck mounted dust extractor. This high performance machine is exclusively
designed and built to be used in combination with the Blastrac 2-45D blast cleaning machine. It is equipped
with 24 pieces of specially designed high quality Blastrac cartridge filters. The rotating valves transport all
generated debris directly into 2 BigBags for easy removal.
The Blastrac dust extractor 2-45TDC can only be used for dry cleaning.
It should only be used for removing noncomb stible/non-explosive d st or s bstances.
The 2-45TDC may not be used for carcinogenic or pathogenic s bstances.
The machine is designed for usage in conditions according to classification M (see below).
Classification acc. standard EN 60335-2-69 – Annexe AA
Class Designation
L
(light hazard) suitable for separating dust with a limit
value of occupational exposure of
greater than 1 mg/m³
M
(medium hazard) for separating dust with a limit
value of occupational exposure not
less than 0,1 mg/m³
H
(high hazard) for separating all dusts with all limit
values of occupational exposure,
including carcinogenic and pathogenic dusts.

9
In the case of dust harmful to health, contact the local health and safety authorities, and observe national
regulations in force both during use and disposal.
In addition to the Operating Instructions general and legal regulations regarding accident prevention and
environmental protection must be complied with and indicated!
Such duties may for example relate to the handling of hazardous substances or to the provision and wearing of
personal protection equipment as well as compliance with traffic regulations.
D st emissions into the environment
Class Val e of performance
L Retains at least 99 % of Most Penetrating Particle Size (MPPS) 0. µm
M Retains at least 99,9 % of Most Penetrating Particle Size (MPPS) 0. µm
H Retains at least 99,995 % of Most Penetrating Particle Size (MPPS) 0. µm
1 Compressor 6 Pressure tank with valves
2 Blower / connection to filter unit 7 Cartridge filter chamber
Silencer / Air outlet 8 Dust hopper
4 Connection to blast machine 9 Rotating valve
5 Connection to blower 10 BigBag adapter / Dust outlet

10
The air streaming through the complete system during the application of
the blast cleaning machine and dust extractor 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 the dust from the re-useable abrasive
-Transport of the dust to the dust collector
The dust extractor is provided with an air pulse cleaning system which increases the life of the filter cartridges.
This system works by use of pressurized air, built up by a belt driven compressor. The air is led through a
water separator to the pulse system.
The conditioned air then passes a control valve which regulates the system pressure, and then builds up
pressure in the pulse tank.
The pressurized air is used to generate a pulse of air which cleans the filters from the inside. With every pulse
of the pulse system all dust and particles are released from the filter surface and end up in the dust hoppers
below the filters, where it travels through the rotating valves to be stored in big bags.
The electrobox controls all electronic components, the main switch should be turned off every time after the
job is done. The diagrams of the electrical system are placed inside the control panel.
The touch screen and the electrobox both have to be turned on for either of them to work.
The truck’s engine power is transmitted to the hydraulic PTO (1 ), to allow smooth
driving at low speeds and ensure high blasting power from the blast unit. The
hydraulic system runs at or below 250 bar.
During transport the blast unit has to be stored inside the truck. Use the safety
chains to secure it inside.
Inside the truck you will also find a toolbox mounted to the wall and a powder fire
extinguisher. This powder extinguisher is suited for: Solid materials (A), Liquids (B),
and Gasses (C). It is also safe to use on electrical components under current
(minding the collateral damage).
11 Electrobox
12 Touch screen inside the cabin
(PLC)
1 Oil tank for hydraulic system
(PTO)
14 2-45D Blast cleaning machine
11
12
1
14