Clemco BNP Series User manual

Revision: 3.3
Clemco
International GmbH Carl-Zeiss-Straße 21 Tel.: [phone] – 90080
83052 Bruckmühl Mail: [email protected]
Germany Web: www.clemco-international.com
OWNER’S MANUAL
Pressure Blast Cabinet
BNP series
(BNP 65, 75, 85, 220, 601& 721)

2
INDEX
1ABBREVIATIONS, DEFINITIONS, SYMBOLS AND ICONS....................................................................4
2PRODUCT DESCRIPTION.........................................................................................................................4
2.1 Conventional utilization and restrictions..................................................................................4
2.2 No conventional utilisation – Warnings for misuse ...................................................................4
2.3 Operating mode of the complete system..................................................................................5
2.4 Description..........................................................................................................................7
2.4.1 Media-recovery system (Cyclone).....................................................................................................7
2.4.2 Blast machine..................................................................................................................................7
2.4.3 Dust collector cartridge....................................................................................................................7
2.4.4 Control elements .............................................................................................................................8
2.5 Energy consumption .............................................................................................................8
2.6 Emissions............................................................................................................................8
3SET-UP FOR INITIAL INSTALLATION ...................................................................................................8
3.1 Carriage / Handling...............................................................................................................8
3.1.1 BNP 65 and BNP 220 ......................................................................................................................8
3.1.2 BNP 75 und BNP 85........................................................................................................................9
3.1.3 BNP 601 and BNP 721 ..................................................................................................................10
3.1.4 Cyclone ........................................................................................................................................10
3.2 Unpackung and disposing the packing material ......................................................................10
3.3 Requirements.....................................................................................................................10
3.3.1 Required space for : BNP 65 and 220..............................................................................................11
3.3.2 Required space: BNP 75 and BNP 85..............................................................................................11
3.3.3 Required space for BNP 601...........................................................................................................12
3.3.4 Required space for BNP 721...........................................................................................................12
3.4 Set-up, assembling and operation checkout............................................................................13
4INSTRUCTION HANDBOOK...................................................................................................................14
4.1 Set up and operation, Shut down...........................................................................................14
4.2 Emergency stop..................................................................................................................14
4.3 Shut down by longer interruption of work or moving the cabinet..............................................15
4.4 Special procedures..............................................................................................................15
4.4.1 Depressurizing ..............................................................................................................................15
4.4.2 Adjust media / air mixture..............................................................................................................15
4.4.3 Negative pressure, view, media consumption and flow .....................................................................16
4.4.4 Media unloading............................................................................................................................16
4.4.5 Pulsing (cleaning) dust collector cartridge / replace cartridge / disposal of residues.............................17
4.4.6 Window replacement .....................................................................................................................17

3
4.4.7 Adjust door safety interlook............................................................................................................18
5MAINTENANCE AND CLEANSE ............................................................................................................18
5.1 Preface..............................................................................................................................18
5.2 If required..........................................................................................................................18
5.3 After max. 8 h of blasting....................................................................................................18
5.4 After max. 50 h of blasting ..................................................................................................19
5.5 After max. 150 h of blasting.................................................................................................19
5.6 After other periodes of time .................................................................................................19
6TROUBLESHOOTING .............................................................................................................................19
7ADMITTED MODIFICATIONS FOR USERS ..........................................................................................21
8REPLACEMENT PARTS..........................................................................................................................22
8.1 Replacement parts BNP 65, BNP 75, BNP 85 and BNP 220 ....................................................22
8.2 Replacement parts BNP 601 and 721 ....................................................................................23
8.3 Pneumatic circuit................................................................................................................25
8.4 Blast machine ..................................................................................................................26
8.5 Nozzles, Blast hose, Couplings, etc.......................................................................................26
8.6 Foot pedal..........................................................................................................................28
8.7 Cyclon pression..................................................................................................................29
8.8 Dust collector and blower....................................................................................................31
8.9 Control box........................................................................................................................31
8.10 Options - different voltage and power................................................................................31
8.11 Grounding......................................................................................................................32
8.12 Options, Accessories........................................................................................................32
8.12.1 Further options..............................................................................................................................33

4
1Abbreviations, definitions, symbols and icons
Risk of injuri!
Connect electric circuit points
only by authorized electrician
Electrostatic strokes!
Ground!
Noise > 85dB(A)!
Wear ear protection
Explosion hazard caused by dust!
Ground!
Explosion hazard!
Connect only max. admitted
pressure.
Risk of injuri!
Dicharge completely pressure during
maintenance jobs.
2Product description
Remarks
Cabinet
none
Cyclone
none
Blast machine
Pay attention to the owners manual of the used type
Dust collector
Pay attention to the owners manual of the used type
2.1 Conventional utilization and restrictions
BNP 65 / 75
BNP 220 / 85
BNP 601
BNP 721
Max. loading rate of the grate /floor 1000 N
100 kp
1000 N
100 kp
2500 N
250 kp
2500 N
250 kp
Max. loading rate of the housing 2000 N
200 kp
2000 N
200 kp
10 000 N
1000 kp
10 000 N
1000 kp
Max. load rating with rack (standard ) 2000 N
200 kp
2000 N
200 kp
2500 N
250 kp
2500 N
250 kp
Operating time
Continuous duty
Basic parameters
See attached yellow cover
2.2 No conventional utilisation – Warnings for misuse
Utilization is interdicted:
As a blow –off cabinet in use of explosive and/or harmful solvents
- in explosion hazard zones
- for blasting parts, where hazardous materials were released
oby explosion hazards
owhich where not retained enough by the dust collector
owhich causes damages caused to somebodys health during a defectuous dust collector

5
2.3 Operating mode of the complete system
Abrasiv circiut flow - Basic principle
1
4
9
11
Pure air
9 / -QN1
Manual abrasive metering valve
Abrasive, dust and air
10 / -QM2
Diaphragm valve /cleaning
Abrasive and air
11 / -QM4
Outlet valve
Dust and air
- - / -RM1
Dust
- - / -BG1
1 / -HS1
Moisture separator, dust collector
- - / -BP2
2 / -QM3
Ball valve
3 / -KH1 + -KH2
Pilot regulator
X1
Blast cabinet
4 / -KH3
Pressure regulator auch Einlaßventil
X2
Reclaimer
5
Pneumatic door interlock - 3/2-way solenoid valve
X3
Cartridge dust collector
6 / -RM1
Nozzle
X4
Exhaust muffler
7 / -QM1
3/2-way solenoid valve
X5
E-box
8 / -SJ1
Foot pedal 3/2-way solenoid valve
X7
Blast machine

6
Pneumatical flow scheme
-HS 1
12
3
-KH 1
12
3
-KH 2
-PG 1
-PG 3
12
3
-KH 3
-QM 3
-CM 1
-MB 2
-RN 3
-RN 2
Abblasdüse Hand /
Cleaning nozzle
Soufflette manuelle
Filterreinigung /
Filter cleaning
Nettoyage des cartouches
Fußpedal Strahlen /
Foot pedal blasting
Pédale sablage marche
2
1
-QM 2
2
13
-QM 1
Druckluft /
Compressed air /
Air comprimé
(max.10 bar)
2
1
12
-QM 4
1
2
-RM 1
-MB 2
-RN 4
2
1
-QM 5
Strahldruck /
Blast pressure/
Pression de sablage
-RN 1
1
3
2
-BP 2
Staubkübelüberwachung /
Dust bin in place
Surveillance fut à poussières
Freigabe Filterreinigung /
Filter cleaning enabled /
Validation nettoyage cartouches filtrantes
2
13
-BG 2
-YV 1
2
13
-SJ 1
Freigabe Strahlen/
Blasting enabled/
Validation sablage
2
13
-BG 1
Anzahl abhängig von Filtergröße /
Number depending on filter size
Nombre en fonction de la taille du filtre
Anzahl abhängig von Filtergröße /
Number depending on filter size
Nombre en fonction de la taille du filtre
Kesselentlüftung /
Blast pot ventilation
Dépressurisation sableuse
Dosierventil /
Dosing valve /
Vanne de dosage
Verteilerblock Kabinenrückwand /
Distribution block at rear wall of cabin /
Boîte de dérivation
-QN 1
2
1
12
-QM 6
2
12
31
-QM 7
-QM 9
-QM 8
RMS 1500
TLR

7
2.4 Description
BNP 65 or BNP 220
BNP601 or 721
BNP 75 and BNP 85
2.4.1 Media-recovery system (Cyclone)
- Cyclone principle
- Deposition of:
oDust in dust collector
oGood media in circuit
oCoarse impurities in screen
2.4.2 Blast machine
oVolume: depending of the model
oMedia metering valve: manual or pneumatic
oControlled by foot pedal
2.4.3 Dust collector cartridge
oStandard: cartridge dust collector MBX
oAutomatically cleaning with jet pulse and after running process

8
oRecommandations for MBX-Filter
oPulse interval: ca. 40..60 s
oPulse duration: ca. 500 ms
oFollow up cleaning: ca. 5min
oexchangeable cartridge.
oDust container
2.4.4 Control elements
where
notes /functiones
Pressure regulation blasting
Control box
2 to 7 bar
Dedusting filter cartridge
Pressure regulator on air balance
vessel – Backside of blast cabinet
Preference pressure: 5 bar
ON/OFF
Control box
Activating:
- Control circuit
-Fan
-Light
-Filter cartridge dedusting function
(After running process)
Emergency STOP
Control box
Deactivating electrical supply
2.5 Energy consumption
- air consumption: see yellow cover
- electrical connection: see machine shield
2.6 Emissions
See yellow cover.
3Set-up for initial installation
3.1 Carriage / Handling
3.1.1 BNP 65 and BNP 220
A
G
G
G
Min 45°
BNP
Weight
A (mm)
65
2500 N
250 kg
1100
220
2800 N
280 kg
1450

9
3.1.2 BNP 75 und BNP 85
G
G
BNP
Weight
A (mm)
B (mm)
75
5000N
500 kg
2200
1200
85
5600 N
560 kg
2900
1300
G
GG

10
3.1.3 BNP 601 and BNP 721
G
GG
Min 45°
BNP
Gewicht
A (mm)
601
8000 N
800 kg
1500
721
10 000 N
1000 kg
1850
3.1.4 Cyclone
A
GG
Min 90°
Type
weight
A (mm)
900
500 N
50 kg
800 mm*)
1200
700 N
70 kg
800 mm*)
3.2 Unpackung and disposing the packing material
- Pallet: Wooden pallets 800 x1200
- Plastic film
3.3 Requirements
- basic allowance: see yellow cover sheet

11
3.3.1 Required space for : BNP 65 and 220
picture 3: Required space for BNP-65 & 220 with stand alone cyclone and MBX-filter
Pos 1
BNP 65( left) und BNP 220 (right)
Pos 2
Cyclon (900 oder 1200 CFM) + blast pot
Pos 3
MBX Filter 1500 CFM
3.3.2 Required space: BNP 75 and BNP 85
Ca.1320
BC
Ca.4450
Ca.6750
Arbeitsfläche
800 mm breit
Ca.800
Ca.800
A
Ca.1440
Filter
Kabine
Zyklo n +
Kessel
Ca.4100
BNP 75
BNP 85
A (mm)
910
1000
B (mm)
2120
2850

12
3.3.3 Required space for BNP 601
Pos 1 = Cabinet BNP 601
Pos.2 = Car with turntable
Pos.3 = Filter MBX (1500;2000)
Pos.4 = 900 CFM Cyclone and blast machine
Picture 4a: Required space for BNP-601
3.3.4 Required space for BNP 721
Pos 1 = Cabinet BNP 721
Pos.2 = Car with turntable
Pos.3 = Filter MBX 1500
Pos.4 = 900 CFM Cyclone and blast machine
Picture 4b: Required space for BNP-721

13
3.4 Set-up, assembling and operation checkout
Cabinet set-up. -Requirements: see yellow cover
-Bracing in the floor not necessary
Warning! Explosion hazard!
Connect only max. admitted pressure
Air supply - max. 7 bar
- for higher pressures install pressure regulator and safety valve between cabinet and air
supply
-air hose between air supply and cabinet:
+ Inner diameter : min 19 mm
+ Lenght: max. 10m
Filter cartridge dedusting
Adjust pressure regulator for dedusting to 5 bar
Warning! Risk of injuri!
Connect electric circuit points only by
authorized electrician.
Warning! Explosion hazard caused by
dust!
Ground!
Caution! Risk of injuri!.
Ground!
Electrical connection and
grounding -16A Euro plug connector
-Ground cabinet, cyclone and dust collector
- min 10 mm2
- earth screw in stock, ground wire etc. no shipment
Caution! Noise > 80dB(A)
Wear ear protection!
Operation checkout without
media Close the doors.
Switch-on elctricity (green push button). Control the following:.
-Is lighting on?
-Is the fan motor starting?.Turns the motor in direction of the arrow? Otherwise reverse
the polarity.
-Is dedusting pulse for cartridge filter activ ? ( Interval. ca 40 s)
-Take the nozzle in your hand and press the foot pedal.. Is the blast process starting?
-Step on the foot pedal und open left resp. right door ( 2. person. Is the blast process

14
stopping?Test cabinet with media, if no irregularities can be detected. Otherwise
remedy errors. Therefor see section 6.
Media loading - Exhauster off.
- add media slowly into reclaimer hopper through the reclaimer door (blast pot).
- Media capacity (initial fill)
+Blast machine: 20l: 12l abrasive
+Blast Machine : 40l: 25l abrasive
+Blast machine: 100l: 60l abrasive
+Blast machine: 200l: 120l abrasive
Operation checkout with
media -Close doors.
- adjust blast pressure.
-
Hold nozzle in direction grate. Step on the foot pedal Blast process starts
Check, if dust passes of (second person). Critical zones:
-Doors
-suction hose connections
-Connections between dust collector and dust container. Leak tightness can be
remarked only during dedusting.
4Instruction handbook
4.1 Set up and operation, Shut down
Turn on air supply
Adjust blast pressure
Switch on electricity
Main switch and green push button
Load parts to be b
lasted into
the cabinet
Close doors
Blasting
Hold blast gun/nozzle and step on the foot pedal
Blow off media
Clean parts with blow off gun
Disconnect electricity -Main switch
- Red push button
- Dedusting process works still for ca. 5 min
Disconnect air supply
4.2 Emergency stop
Push emergency stop
button
Electrical supply is disconnected, dedusting too
-depressurizing the
installation
see 4.4.1
Clarification of causation
see 6.

15
4.3 Shut down by longer interruption of work or moving the cabinet
Remove media
see 4.4.4.
Disconnect electricity
Authorized electrician
Depressurize
installation
see 4.4.1.
4.4 Special procedures
4.4.1 Depressurizing
Close external air supply
Depressurize moisture separator over drain
screw
4.4.2 Adjust media / air mixture
The following steps must be followed in order to operate the
manual Quantum metering valve:
1. Start the blast operation
2. Turn the metering knob
The manual metering valve adjusts abrasive flow by turning the
metering knob.
Pneumatic PT-valve
- Close metering valve
- open step by step. Blast jet is ok when the blast media comes
out the nozzle as a light mist

16
4.4.3 Negative pressure, view, media consumption and flow
Damper
Negative pressure
View
Media exhausting /
Consumption
Media suction
1
lower
better
higher
better
2
higher
worse
lower
worse
4.4.4 Media unloading
Turn on exhauster
Green push button
Unloading the blast pot - Close choke valve on the blast pot
- fully open media metering valve
- Blasting pressure: low as possible
- unscrew nozzle and nozzle holder
- put a container such as a bucket on the cabinet grating
- hold hose into the container
- press foot pdeal direct media flow into the conatiner
Cleaning cabinet -closed doors
-exhauster is working
-with blow off nozzle
Unloading the reclaimer / cyclone
-open door and remove media into the blast pot
Unloading blast pot again
-only residues
BNP 65 & BNP 220
BNP 601 & 721
1
2
2
1

17
4.4.5 Pulsing (cleaning) dust collector cartridge / replace cartridge / disposal of residues
Replace cartridge - pulse filter cartridge two times
-start again cabinet and turn off after more than 2min 
+ ca. 5 minutes dedusting pulse
- push emergency stop
- close air supply
- depressurize installation (see 4.4.1)
- unscrew filter cover
- pull a ( ≥ 120 l) plastic bag over the filter cartridge
- unscrew the nuts on the flange and pull out the filtercartridge with the
plastic bag.
- screw the new filter cartridge and take care of the position of the seal kit.
- Close dust collector cover
Empty dust container
-
release the dust container from the cover
WARNING!If toxical residues, dispose dust as hazardous waste!
4.4.6 Window replacement
No.:
Description
1
Filler strip
2
molding
3
Place for filler strip
4
Cabinet wall (fits into narrow slot)
5
Window tool
6
Filler strip
7
window (fits into expanded slot)
Pull filler strip from the window molding
Remove window
Push the window from the cabinet inside
Install a new window molding
Strip channel facing the front of the cabinetg
Install window
Push into the slot
Thread filler strip
With installation tool

18
4.4.7 Adjust door safety interlook
Nr:
Description
1 Door safety interlock
2 Nut for screw adjusting
3 Actuating screw for safety interlock
4 Cabinet door
5Maintenance and cleanse
5.1 Preface
During operation the cabinets are exposed to wear. In order to ensure safe operation and high efficiency the blast machines
must be maintained regulary.
Warning! Risk of injuri!
Dicharge completely pressure during maintenance
jobs. (see 4.4.1)
5.2 If required
Check and if necessary. replace /cleanse
View window -cover lenses
-if necessary window glass – see 4.4.6
gloves
5.3 After max. 8 h of blasting
Check and if necessary. replace /cleanse
Door interlock -Open doors
- press pin (1). It has to return from alone.
Empty dust container.
- could be necessary already after one hour
Media recovery system (Reclaimer). -empty screen Turn off exhauster. This may be necessary more often - screen
magnet .
Nozzle and nozzle holder
Check gasket for wear and replace if it’s necessary

19
5.4 After max. 50 h of blasting
Check and if necessary. replace /cleanse
(1) Blast gun and nozzle
Nozzle gasket.
(2) Moisture separator.
Clean filter and sight glass with soap and warm water
(3) Air hoses and blast hoses. - gaskets of couplings for wear
-blast hose by hand for soft spots
(4) Blast pot - pop up valve for wear by hand
-Verschleiß Verschlußkegel durch Abtasten mit Fingern überprüfen
5.5 After max. 150 h of blasting
(1) Gasket on cabinet doors.
(2) Filter cartridge.
- see 4.4.5
5.6 After other periodes of time
replace (even without wear) after maximal
Blsat hoses
6 years
Remote control hoses
6 years
Air hoses – external air supply
6 years
O-rings
5 years
Pop up valve (blast pot)
5 years
Gaskets
5 years
6Troubleshooting
Problem
Probable cause
Remedy
(1) Poor visibility.
Exhaust motor does not rotate.
Slide damper in false position
See 4.4.3
Dirty filter cartridge. Blow off filter cartridge.
replace (see 4.4.5).
Exhaust motor rotates in the wrong
direction.
Reverse polarity (only through licensed electrician).
Blast media breaks down rapidly
and creates dust - lower blast pressure
- other media.
Blocked hose between blast
cabinet and reclaimer / cyclone
Check and if necessary disassemble hose and remove
dust and media.
Blockage is not the real cause.
Negative pressure. Check the following components:
- Reclaimer door open or leaky.
- Test the connections of hose for leaks
- Suction hoses for wear.
- Dust leaking from dust conatiner

20
(2) Abnormally high
media consumption.
Cyclone door open or leaky. Replace gasket.
Too fine or too lighweight media.
Install and adjust supplementary a Vortex cylinder.
Negative pressure to high
See 4.4.3
(3) Poor cleaning rate.
Not enought blast media in circuit.
Check and if necessary refill.
Media metering valve is adjusted
incorrect
A new adjustment is necessary (see 4.4.2).
Reduced air-pressure - Check air supply
- If the static pressure decreases during blasting, the
following components should be checked :
+ moisture separator
+ pressure regulator
+ nozzle
Blocked blast hose or gun / nozzle. - Push nozzle against an elastical object (for example
rubber plate) and step on the foot pedal.
- Disassembly hose or gun and cleanse.
- Search after the cause of blockage:
⇒Missing or overfilled screen in the
reclaimer.
⇒Incorrectly adjusted metering valve.
⇒
Too heavy blast media.
Worn nozzle
-remove / change nozzle
Moist blast media.
−Frequent bridging or blockage in the media
metering valve can be caused by moist blast
media. Following reasons could be possible:
⇒Media was filled moistly remove
⇒Humidity from air supply interconnect
humidifier
⇒Perspiration water caused by sharp drop in
room temperature Make sure, that there is
not too much temperature fluctuation
(4) Dust comes out the
blower
Dust filter gasket defective. -replace gasket -see 4.4.5
Defective cartridge.
- replace cartridge -see 4.4.5
(5) Static shocks - improve grounding of the cabinet.
- in exceptional cases use supplementrary ground wire
between blast gun and cabinet wall
(6) No air and no media
comes out the nozzle
Door interlocks are not actuated Adjust pin resp. door fixing bzw. see 4.4.7
Wrong connection of pneumatic
hoses on foot pedal permanent
air blow off
- only when foot pedal was new installed
- connect properly
Polluted (blocked) moisture
separator.
Cleanse moisture separator
Hose of control lines leaky
- need of second person