Clemco HS-200P-1 User manual

Revision: 01
Clemco
International GmbH Carl-Zeiss-Straße 21 Tel.: [phone]
83052 Bruckmühl Mail: [email protected]
Germany Web: www.clemco-international.com
OWNER’S MANUAL
Dustfree, portable blast machine
HS-200P-1

2
TABLE OF CONTENTS
1SCOPE OF MANUAL ...........................................................................................3
2APPLICATION AND RESTRICTIONS..................................................................3
3GENERAL DESCRIPTION....................................................................................3
3.1 COMPONENTS .............................................................................................................3
3.2 AIR REQUIREMENTS.....................................................................................................5
3.3 HOW THE SYSTEM WORKS............................................................................................5
4INSTALLATION ....................................................................................................6
4.1 SET-UP FOR INITIAL INSTALLATION OR REINSTALLATION .................................................6
4.2 DAILY SET-UP..............................................................................................................7
4.3 OPERATION ................................................................................................................8
4.4 SHUT DOWN................................................................................................................8
4.5 SHUT DOWN WHEN MOVING EQUIPMENT........................................................................9
5MAINTENANCE ....................................................................................................9
5.1 GENERAL....................................................................................................................9
5.2 DAILY CHECK LIST .......................................................................................................9
5.3 WEEKLY CHECK LIST....................................................................................................9
5.4 MONTHLY CHECK LIST................................................................................................10
6TROUBLE-SHOOTING.......................................................................................10
7REPLACEMENT PARTS ....................................................................................12
7.1 SYSTEM....................................................................................................................12
7.2 BLAST HEAD EDBH 70 AND 90-I.................................................................................15
7.2.1 Blast head EDBH 70 .........................................................................................................15
7.2.2 Blast head EDBH 90-I.......................................................................................................16
7.3 REVERSE PULSE DUST COLLECTOR ............................................................................17

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1 Scope of manual
This manual covers set-up, operation and maintenance of the dustfree, portable blast machine HS-
200P-1.
Additionally the owner’s manual "Remote control valves RMS-2000, 1500, 500“ should be considered.
2 Application and restrictions
This dustfree blast machine is mainly applied for blast cleaning of parts which cannot be blasted in a
cabinet or blast room (because of their size, weight or long distance for transportation). The design
allows local blast cleaning on a part without the escape of abrasive, dust or debris into the environment.
All type of blast media can be used. When using glass beads or plastic media a special design for the
impact separator is necessary.
The blast machine is rated for a maximum working pressure of 8 bar.
3 General description
3.1 Components
Figure 1 HS 200 P-1.

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Figure 1 shows the major components:
Chassis (L x B x H = 1.400 x 790 x 2.200 mm, weight approx. 300 kg) with mounted
pot and silo.
reverse pulse dust collector.
air manifold.
Pot with integrated silo
Volume 40l each (pot and silo respectively).
Maximum working pressure 12 bar.
60 degree cone.
Abrasive metering valve
Removable screen.
Impact separator with rubberized plate (for glass beads and plastic media on
request).
Reverse pulse dust collector with
filter cartridge (filter area 8 m2 ).
suction unit.
dust container.
Air manifold with
1 inlet valve RMS-1500.
air relief valve.
moisture separator.
air connection.
Blast head EDBH-90-1 or EDBH-70
Nozzle SMR-4 (standard).
Nozzle CSD-4/B (boron carbide) for aluminium oxide.
Flat and elbow brush.
Hoses between pot / silo und blast head
PU-suction hose 2“ with couplings.
Blast hose 25 x 7 mm or 19 x 7 mm with couplings.
Deadman handle with twinline hoses (mounted on blast hose).
3-way slide valve (suction unit On / Off) with twinline hose.

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3.2 Air requirements
Air consumption suction unit: approx. 4,3 m3/min. at 8 bar.
Air consumption with 6,5 mm nozzle: approx. 3 m3/min. at 7 bar.
3.3 How the system works
(See Figure 2: Plumbing assembly.)
When the air supply is on, compressed air enters the air manifold via the moisture separator (item 1).
When the 3-way slide valve (item 18) is closed, the right inlet valve RMS-1500 (item 2) opens and
frees the supply air for the suction unit (item 20) and the deadman handle (item 17). The suction unit
turns on.
When the deadman handle (item 17) is depressed, the outlet valve (item 6) closes,
and the pot is pressurized (pop-up valve item 4 closes). The blast process starts. The working
pressure is adjusted with the pressure regulator (item 3).
After hitting the surface abrasive and debris are drawn into the blast head (item 16) and guided
(suction hose item 15) to the impact separator (item 30). The coarse, reusable media is screened (item
10) and falls into the silo. The suction unit (item 20) draws the dust into the reverse pulse dust
collector (item 23).
When the deadman handle is released (item 17), the outlet valve (item 6) opens ,
and the blast process interrupts (the pot is depressurized). The blast media in the silo falls through
the filling port into the pot.
When the 3-way slide valve (item 18) is opened the suction unit turns off and the filter cartridge is
cleaned through a pulse of compressed air. With the pressure regulator (item 25) the air pressure
for pulsing is adjusted (max. 7bar)

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4 Installation
4.1 Set-up for initial installation or reinstallation
(1) Place the blast machine.
Firm and even ground.
(2) Install air supply.
Start the compressor and bring it up to operating temperature
(5 to 10 min.). Only use compressors whose rating do not
exceed 8 bar!
Attach an air line (appropriate dimension) with all necessary
gaskets in place to the air outlet of the compressor and safety
lock the couplings. Escaping air is dangerous and lowers
efficiency!
Carefully open the air valve of the compressor to blow debris
and moisture out the attached air line.
Close the air valve.
Connect the air line to the blast machine and safety lock it.
For troublefree blasting we recommend an air supply free of oil
and water (air cooler with cyclone and automatic drain).
(3) Connect the blast hose, suction
hose and the remote control
hoses.
Connect the blast and suction hose to the blast machine and
safety lock them.
Check that all gaskets are in place.
Connect both twinline hoses (yellow / brown and red / blue)
to the corresponding twinline hoses coming from the blast
machine.
Attention! A reversed connection causes malfunction and
danger of injuries!
(4) Choose the right brush.
Flat brush for flat surfaces.
Elbow brush for edges.
(5) Put on the protective equipment.
Abrasive-resistant clothing.
Eye protection, for example goggles with safety glass.
Leather gloves.
(6) Check moisture separator, pulse
pressure and remove moisture
from the blast machine.
Open the air valve of the compressor.
Open the ball valve.
Check pulse pressure (regulator knob with gauge on the
suction unit). Maximum pressure 5 bar.

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Adjust the drain of the moisture separator, so that a constant
stream of liquid and air is expelled under pressure.
Fully open the media metering valve.
Close 3-way slide valve (suction unit turns on).
About 3 min. hold the deadman handle depressed (the pot is
pressurized and air comes out the nozzle), in order to remove
moist.
Release the deadman handle.
4.2 Daily set-up
Not necessary if an initial installation or reinstallation was performed (see section 4.1).
(1) Install an air supply.
Start the compressor and bring it up to operating temperature
(5 to 10 min.). Only use compressors whose rating do not
exceed 8 bar!
Connect an air line to the compressor’s air outlet and remove
moist.
Install all necessary gaskets and safety lock the couplings.
Escaping air is dangerous and lowers efficiency!
Connect the air line to the blast machine and safety lock it.
(2) Put on the protective equipment.
Abrasive-resistant clothing.
Eye protection, for example goggles with safety glass.
Leather gloves.
(3) Check the moisture separator,
pulse pressure and remove
moist from blast machine
(longer standstill).
Open the air valve of the compressor.
Open the ball valve.
Check pulse pressure (regulator knob with gauge on the
suction unit). Maximum pressure 5 bar.
Adjust the drain of the moisture separator, so that a constant
stream of liquid and air is expelled under pressure.
Fully open the media metering valve.
Close 3-way slide valve (suction unit turns on).

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Hold the deadman handle about 3 min depressed (the pot is
pressurized and air comes out the nozzle), in order to remove
moist.
Release the deadman handle.
4.3 Operation
(1) Load abrasive into the blast
machine.
Only when the blast machine is fully empty!
Close metering valve (turn the metering knob to the right).
Pour abrasive (30 to 40L) on an even surface.
Close the 3-way slide valve (suction unit turns on) and
through the blast head draw the abrasive into the blast
machine (the abrasive will immediately be cleaned).
(2) Media metering. (2 persons are
necessary).
Place the blast head vertically on the work surface.
Close 3-way slide valve (suction unit turns on).
Depress deadman handle.
Second person slowly opens the metering valve until enough
blast media comes out the nozzle (blast pattern and noise).
Release deadman handle.
(3) Operation.
Place the blast head vertically on the work surface.
Depress deadman handle (the blast process starts).
Slowly move the blast head according to the blast progress.
4.4 Shut down
(1) Completely remove abrasive.
To Prevent blockage from moist abrasive (longer standstill of
blast machine).
Reduce working pressure to 0,5 bar.
Fully open the media metering valve.
Turn on suction unit (3-way slide valve).
Depress deadman handle.
Empty the abrasive into a container.

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4.5 Shut down when moving equipment
No special measures required.
5 Maintenance
5.1 General
During operation blast machines are exposed to wear. In order to ensure safe operation and high
efficiency the blast machines should be maintained according to the following check lists.
Prior to maintenance, make sure that the air valve of the compressor is closed and the whole
system is depressurized!
5.2 Daily check list
(1) Pot.
Open inspection door.
Check the gasket and the pop-up valve of the filling port by
hand for wear.
(2) Air, suction and blast hose.
Check the hoses for sharp bends, causing high loss of energy
and rapid wear.
No vehicles should pass over hoses!
Check the gaskets of the couplings.
(3) Nozzle.
Check the nozzle gasket and replace it at the first sign of wear.
Check the nozzle for wear and replace it if necessary.
(4) Remote control valves and
accessories.
Open the petcock of the remote control valve RMS-1500 and
check for water. If water is detected check the moisture
separator (see section 5.3).
Check the fittings of the remote control valves for tightness.
(5) Dust container.
Empty dust container.
5.3 Weekly check list
(1) Moisture separator.
Remove and check the filter element. If necessary clean the filter
and the sight glass with soap and warm water and dry it with
compressed air.
A dirty filter causes loss of pressure in the system!
(2) Air, suction and blast hoses.
Check all couplings and screws for wear or breakage and
replace them if necessary.

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Check the whole blast hose by hand for soft spots (reduced
wall thickness) and replace it immediately when soft spots are
detected.
Check the air line (air supply) and replace it when it is worn.
Check the gaskets of couplings for wear and replace them if
necessary.
5.4 Monthly check list
(1) Remote control valve RMS-1500
respective outlet valve
Check all fittings and connections of the remote control valve for
leakage.
6 Trouble-shooting
Problem
Probable cause
Remedy
(1) No air and no abrasive
comes out the nozzle.
Turned off compressor.
Turn on compressor.
Blocked moisture separator.
Check and clean.
Inlet valve RMS-1500 doesn’t
work.
Close 3-way slide valve.
Depress deadman handle.
Check valves and control
hoses for loose connections.
(2) Air, but no abrasive comes
out the nozzle.
Closed metering valve.
Open it.
Moist abrasive blocks the flow of
abrasive at the bottom of the pot.
Several times open and close
choke valve rapidly.
Open the inspection door and
clean the pot.
Not enough air volume.
Use a bigger compressor.
(3) Irregular flow of abrasive
comes out the nozzle.
Incorrectly adjusted abrasive
metering valve.
Check adjustments.
Choke valve not fully opened.
Check and fully open it.
Blocked metering valve.
Open and clean metering valve.

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(4) Too much abrasive comes
out the nozzle.
Metering valve too much
opened.
Check and correct adjustments if
necessary.
Choke valve not fully opened.
Check and fully open it.
(5) Pop-up valve doesn’t remain
closed.
Not enough air volume or
pressure.
Check air pressure of the
compressor with a needle
gauge.
Close the choke valve. When
the pop-up valve does not
seal the filling port completely,
there is not enough air
volume.
(6) Pop-up valve does not close
after depressurization.
Worn pop-up valve and / or
gasket.
Replace the pop-up valve and / or
the gasket.
Blocked guide for the pop-up
valve.
Open inspection door.
Remove the pop-up valve and
clean the blast machine.
(7) Blast machine does not
depressurize when the
deadman handle is released.
Blocked outlet valve.
Clean the outlet valve.
Inlet valve RMS-1500 defective.
Check connections.
Check and repair the inlet
valve.
(8) Poor suction (abrasive is not
completely drawn into the
blast machine and escapes).
Not enough air volume or
pressure.
Check air pressure of the
compressor with a needle
gauge.
If necessary use a bigger
compressor.
Blocked moisture separator.
Check and clean.
Clogged filter cartridge.
Turn off the suction unit after a
longer period of work without
interruption (filter cartridge is
cleaned).
Check pulse pressure.
Clean filter cartridge.

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Defective gaskets.
The following gaskets should be
checked for wear and replaced:
Impact separator.
Dust collector.
(9) Suction unit cannot be turned
on.
No air supply.
Install an air supply.
Defective inlet valve RMS-1500.
Check and repair or replace if
necessary.
Defective pneumatic controls.
Check all control hoses and
connections for wear.
Check 3-way slide valve.
7 Replacement parts
7.1 System
(See Figure 2 - Replacements parts HS 200 P-1.)
No.
Stock No.
Model
Description
(-)
99954D
HS-200 P-1
Dustfree, portable blast machine complete
(1)
90545D
HMS
Moisture separator
(2)
100028
RMS-1500
Inlet valve complete
(3)
01906D
Pressure regulator 1¼"
(4)
02321D
P-2
Pop-up valve with external sleeve
(5)
99157D
P-5
Gasket
(6)
03371I
TLR
Outlet valve
(7)
100047
1”
Hose with SKG-25
(8)
02397D
1 ¼”
Ball valve
(9)
22780D
QK-Quantum
Abrasive metering valve
(-)
100832
Gasket (for impact separator)
(10)
99802D
Screen HSP
(11)
90554D
1 ½”
Ball valve
(12)
99702D
2"
Nipple 2” A
(13)
99180D
2"
Coupling
(14)
04351D
19 x 7
Blast hose 10 m
(-)
04305D
25 x 7
Blast hose 10 m
(15)
90067D
2"
Suction hose (PU)
(16)
94342D
EDBH-90-I
Blast head without nozzle

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99942D
EDBH-70
Blast head with nozzles
(17)
100707
RLX III
Pneumatic remote control handle
(18)
99172D
ACS
3-way slide valve
(19)
90734D
Twinline hose complete with couplings 10 m
(20)
99665D
Suction unit
(21)
99762D
Latch
(22)
99200D
ZP-P-15-8
Special filter (reverse pulse dust collector)
(23)
90953D
Filter cartridge
(24)
99946D
Dust container
(25)
99769D
¼"
Pressure regulator
(26)
90024D
N460S
Nipple
(27)
99633D
1¼“
Non return valve
(28)
90067D
Suction hose 2“ (PU)
(29)
90023D
Air relief valve 1“
(30)
99801D
Impact Separator HSP
((31)
100346
3/2 way
Valve
(-)
24217I
½”
Non-return ball valve
(-)
99096D
3/8”
T-pice
(-)
90038D
46/32
Nipple NW32
(-)
99641D
SK-51
Clamp
(-)
99767D
Wheel
(-)
99766D
Wheel steerable with brake
(-)
99676D
Hose package ==>
10 m suction hose 2" PU
10 m blast hose 25 x 7 or 19 x 7
10 m twinline hose complete with couplings

Revision: 01
Figure 2 - Replacements parts HS 200 P-1

Revision: 01
7.2 Blast head EDBH 70 and 90-I
7.2.1 Blast head EDBH 70
Figure 4 Replacement parts EDBH 70.
No.
Stock No.
Model
Description
(-)
99942D
EDBH-70
Blast head new with nozzles
(1)
99994D
70 mm
Flat brush for EDBH-70
(2)
99943D
Diffusor EDBH-70
(3)
94183D
CBST-25 x 6
Nozzle EDBH-70
(4)
99978D
Protection-rubber
(5)
99992D
Brush protection

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7.2.2 Blast head EDBH 90-I
Figure 5 Replacement parts blast head EDBH 90-I.
No.
Stock No.
Model
Description
(-)
94342D1
EDBH 90-I
Blast head without nozzle
(1)
100148
ALU
Nozzle mounting plate
(2)
94342A
Stainless steel
Body
(3)
99504D
Stainless steel
Nozzle guard
(4)
90154D
M6 x 20
Hex. socket head screw
(5)
90294D
Screw for fastener
(6)
90110D
M5 x 8 mm
Grub screws
(7)
99182D
5“
Flat brush
99183D
Elbow brush
(8)
100150
Brush holder
(9)
04256D
32 x 8
Hose
(10)
100087
Brush protection rubber
(-)
100864
SMS-4
Clemlite nozzle ø 6,5 mm
NOZZLE

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7.3 Reverse pulse dust collector
Figure 6 Cartridge filter.
No.
Stock No.
Model
Description
(-)
99200D
ZP-P-15-8
Special filter
(1)
Upper body
(2)
Diaphragm valve pneumatically operated
(3)
90953D
Filter cartridge
(4)
Air manifold
(5)
Hinges
(6)
Inlet manifold rubberized
(7)
Lower part rubberized
(8)
Dust container
The filter cleans in 2 stages:
Stage 1: Air and dust are drawn into the lower part (item 7) of the filter through the inlet manifold (item
6). Coarse material is separated (cyclone).
Stage 2: The fine material is separated through the filter cartridge (item 3). The filter cartridge is
cleaned through a reverse pulse of compressed air when the suction unit is turned of.