Clemco BNP Series User manual

Revision: 4
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
2GENERAL INFORMATION ........................................................................................................................4
2.1 Technical documents .........................................................................................................4
2.2 Other applicable documents...............................................................................................4
3SCOPE OF MANUAL .................................................................................................................................5
4PRODUCT DESCRIPTION.........................................................................................................................5
4.1 Conventional utilization and restrictions .............................................................................5
4.2 No conventional utilisation – Warnings for misuse..............................................................5
4.3 Operating mode of the complete system............................................................................6
4.4 Description.........................................................................................................................7
4.4.1 Media-recovery system (Cyclone) ................................................................................................7
4.4.2 Blast machine................................................................................................................................7
4.4.3 Dust collector cartridge .................................................................................................................8
4.4.4 Control elements...........................................................................................................................8
4.5 Energy consumption ..........................................................................................................8
4.6 Emissions ..........................................................................................................................8
5SET-UP FOR INITIAL INSTALLATION......................................................................................................9
5.1 Carriage / Handling............................................................................................................9
5.1.1 BNP 65 and BNP 220...................................................................................................................9
5.1.2 BNP 75 und BNP 85........................................................................................................................9
5.1.3 BNP 601 and BNP 721...............................................................................................................10
5.1.4 Cyclone .......................................................................................................................................10
5.2 Unpackung and disposing the packing material ...............................................................10
5.3 Requirements...................................................................................................................10
5.3.1 Required space for BNP 65 and 220..........................................................................................11
5.3.2 Required space: BNP 75 and BNP 85........................................................................................11
5.3.3 Required space for BNP 601......................................................................................................12
5.3.4 Required space for BNP 721......................................................................................................12
5.4 Set-up, assembling and operation checkout.....................................................................13
6INSTRUCTION HANDBOOK....................................................................................................................14
6.1 Set up and operation, Shut down.....................................................................................14
6.2 Emergency stop...............................................................................................................14
6.3 Shut down by longer interruption of work or moving the cabinet.......................................14
6.4 Special procedures ..........................................................................................................15
6.4.1 Depressurizing............................................................................................................................15

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6.4.2 Adjust media / air mixture ...........................................................................................................15
6.4.3 Negative pressure, view, media consumption and flow..............................................................15
6.4.4 Media unloading..........................................................................................................................16
6.4.5 Pulsing (cleaning) dust collector cartridge / replace cartridge / disposal of residues.................16
6.4.6 Window replacement ..................................................................................................................17
6.4.7 Adjust door safety interlook.........................................................................................................17
7MAINTENANCE AND CLEANSE.............................................................................................................17
7.1 Preface ............................................................................................................................17
7.2 If required.........................................................................................................................18
7.3 After max. 8 h of blasting..................................................................................................18
7.4 After max. 50 h of blasting................................................................................................18
7.5 After max. 150 h of blasting..............................................................................................18
7.6 After other periodes of time..............................................................................................18
8TROUBLESHOOTING..............................................................................................................................19
9ADMITTED MODIFICATIONS FOR USERS............................................................................................21
10 REPLACEMENT PARTS ......................................................................................................................21
10.1 Replacement parts BNP 65, BNP 75, BNP 85 and BNP 220 ........................................21
10.2 Replacement parts BNP 601 and 721...........................................................................23
10.3 Pneumatic circuit- manual abrasive metering valve.......................................................25
10.4 Blast machine...............................................................................................................28
10.5 Nozzles, Blast hose, Couplings, etc..............................................................................28
10.6 Foot pedal.....................................................................................................................28
10.7 Cyclon pression............................................................................................................29
10.8 Dust collector and blower..............................................................................................31
10.9 Control box ...................................................................................................................31
10.10 Options - different voltage and power ...........................................................................31
10.11 Grounding.....................................................................................................................32
10.12 Options, Accessories....................................................................................................32
10.12.1 Further options ........................................................................................................................33
11 DISPOSAL.............................................................................................................................................33

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1 Abbreviations, definitions, symbols and icons
Risk of injuri!
Connect electric circuit points
only by authorized electrician
Electrostatic strokes!
Ground!
Noise > 85 dB(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.
2 General information
2.1 Technical documents
The technical documents are part of the machine and contains important manufacturer information. The
technical documentation is intended for everyone who uses the cabinet.
These operating instructions provide important information on handling the device. The precondition for safe
working is compliance with all specified safety instructions and handling instructions. In addition, the local
accident prevention regulations applicable to the area in which the device is used and the general safety
regulations must be followed. Read the operating instructions carefully before starting any work! It is part of
the product and must be kept in the immediate vicinity of the device and be accessible to staff at all times.
These technical documents must be made available to all persons who use the blasting cabinet under their
own responsibility. Those responsible for the plant and operation must ensure that the documentation has
been read and understood completely. On the basis of this documentation and taking into account the
industrial safety regulation, appropriate maintenance and test plans as well as operating instructions for the
operating and maintenance personnel must be derived.
NOTE!
The illustrations in these instructions are for basic understanding and may differ from the
actual design of the device.
2.2 Other applicable documents
The following operating instructions must also be noted:
Operating instructions single-chamber pressure blasting devices with manual metering valve, pilot
pressure regulator, TLR outlet valve and water separator
Operating instructions pressure cyclone
Operating instructions for the MBX Filter

5
3 Scope of manual
These operating instructions apply to the following cabinet types. Please also note the operating instructions
for the components used.
Part no.:
Designation of the
cabinet
Components
Blast machine
(pot)
Pressure cyclone
Filter
12611Z
BNP 65 DS
SC 2040
900 CFM (25,4 m³/min)
MBX 1500
12613Z
BNP 220 DS
SC 2040
900 CFM (25,4 m³/min)
MBX 1500
100401
BNP 601 DS
SC 2040
900 CFM (25,4 m³/min)
MBX 1500
100412
BNP 721 DS
SC 2040
900 CFM (25,4 m³/min)
MBX 1500
100749
BNP 721 DS
SC 2040
900 CFM (25,4 m³/min)
MBX 2000
Option
BNP 75 / BNP 85
4 Product description
4.1 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
4.2 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

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4.3 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
- - / -QM2 + -QM 5
Diaphragm valve /cleaning
Abrasive and air
11 / -QM4
Outlet valve
Dust and air
- - / -RM1
Check valve
Dust
- - / -BG1 + BG2
Pneumatic dustbin monitoring
1 / -HS1
Moisture separator, dust collector
- - / -BP2
PE-converter of dustbin monitoring
2 / -QM3
Ball valve
- - / --QM8 + -QM9
Ball valve
3 / -KH1 + -KH2
Pilot regulator
- - / -RN3
Cleaning nozzle cabin
4 / -KH3
Pressure regulator auch Einlaßventil
X1
Blast cabinet
- - / -PG1 + -
PG3
Manometer X2 Reclaimer
6 / -RN1
Blast Nozzle
X3
Cartridge dust collector
- - / -QM1
3/2-way solenoid valve
X4
Exhaust muffler
- - / -RN2 + -
RN4
Cleaning nozzle Filter X5 E-box
SJ 1
Pneum. Fußpedal
X7
Blast machine

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4.4 Description
BNP 65 or BNP 220
BNP601 or 721
BNP 75 and BNP 85
4.4.1 Media-recovery system (Cyclone)
- Cyclone principle
- Deposition of:
oDust in dust collector
oGood media in circuit
oCoarse impurities in screen
4.4.2 Blast machine
oVolume: 100l
oMedia metering valve: manual
oControlled by foot pedal

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4.4.3 Dust collector cartridge
oStandard: cartridge dust collector MBX
oAutomatically cleaning with jet pulse and after running process
oRecommandations for MBX-Filter
oPulse interval: ca. 40..60 s
oPulse duration: ca. 500 ms
oFollow up cleaning: ca. 5min
oexchangeable cartridge.
oDust container
4.4.4 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
4.5 Energy consumption
- Air consumption: see yellow cover
- Electrical connection: see machine shield
4.6 Emissions
See yellow cover.

9
5 Set-up for initial installation
5.1 Carriage / Handling
5.1.1 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
5.1.2 BNP 75 und BNP 85
GG
BNP
Weight
A (mm)
B (mm)
75
5000N
500 kg
2200
1200
85
5600 N
560 kg
2900
1300
G
GG

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5.1.3 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
5.1.4 Cyclone
A
GG
Min 90°
Type
weight
A (mm)
900
500 N
50 kg
800 mm*)
1200
700 N
70 kg
800 mm*)
5.2 Unpackung and disposing the packing material
- Pallet: Wooden pallets 800 x1200
- Plastic film
5.3 Requirements
- Basic requirements: see yellow cover sheet

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5.3.1 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
5.3.2 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

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5.3.3 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
5.3.4 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

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5.4 Set-up, assembling and operation checkout
Cabinet set-up. -Requirements: see yellow cover
-Bracing in the floor: for blast pot and cyclon – other parts 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

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the blast process 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: 100l: 60l abrasive
Operation checkout with
media -Close the 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.
Note: Leak tightness can be remarked only during dedusting.
6 Instruction handbook
6.1 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 blasted 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
6.2 Emergency stop
Push emergency stop button
Electrical supply is disconnected, dedusting too
Depressurizing the installation
see 6.4.1
Clarification of causation
see 8.
6.3 Shut down by longer interruption of work or moving the cabinet
Remove media
see 6.4.4.
Disconnect electricity
Authorized electrician
Depressurize installation
see 6.4.1.

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6.4 Special procedures
6.4.1 Depressurizing
Close external air supply
Depressurize moisture separator over drain
screw
6.4.2 Adjust media / air mixture
QK-Quantum abrasive metering valve
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.
6.4.3 Negative pressure, view, media consumption and flow
BNP 65 & BNP 220
BNP 601 & 721
1
2
2
1

16
Damper
Negative
pressure
View
Media exhausting
/ Consumption
Media suction
1
lower
better
higher
better
2
higher
worse
lower
worse
6.4.4 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 - Doors has to be closed
- 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
6.4.5 Pulsing (cleaning) dust collector cartridge / replace cartridge / disposal of residues
Replace cartridge - Pulse filter cartridge two times
-start cabinet again and turn off after more than 2min 
+ ca. 5 minutes dedusting pulse
- Push emergency stop
- Close air supply
- Depressurize installation (see 6.4.1)
- 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!

17
6.4.6 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
6.4.7 Adjust door safety interlook
Nr:
Description
1 Door safety interlock
2 Nut for screw adjusting
3 Actuating screw for safety interlock
4 Cabinet door
7 Maintenance and cleanse
7.1 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 6.4.1)

18
7.2 If required
Check and if necessary. replace /cleanse
View window
-Cover lenses
-If necessary window glass – see 6.4.6
Gloves
7.3 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
7.4 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
-Check wear oft he pop-up valve by by palpation with fingers
7.5 After max. 150 h of blasting
(1) Gasket on cabinet doors.
(2) Filter cartridge.
- see 6.4.5
7.6 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

19
O-rings
5 years
Pop up valve (blast pot)
5 years
Gaskets
5 years
8 Troubleshooting
Problem
Probable cause
Remedy
(1) Poor visibility.
Exhaust motor does not rotate.
Slide damper in false position
See 6.4.3
Dirty filter cartridge. Blow off filter cartridge.
Replace (see 6.4.5).
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
(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 6.4.3
(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 6.4.2).
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.

20
⇒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 6.4.5
Defective cartridge.
- Replace cartridge -see 6.4.5
(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 6.4.7
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
- First person „is blasting“
- Second person checks leakages on controles
lines
(7) Air only (no media)
comes out the
nozzle
No blast media in the blast
circuit -Refill
Moist media -Remove moist media.
-Remove cause for humid air supply.
Caution! Risk of injuri!
Dicharge completely pressure during maintenance jobs.
(8) No interruption of
blast process when
foo pedal is
released
Foot pedal valve blocked. - depressurize the installation (see 6.4.1)
- replace foot pedal valve
(9) Irregular flow or too
much blast media
comes out the
nozzle
Incorrect adjusted media flow. Adjust new (see 6.4.2).