Clemco Pulsar II User manual

Revision:1.1
Clemco
International GmbH Carl-Zeiss-Straße 21 Tel.: [phone] – 90080
83052 Bruckmühl Mail: [email protected]
Germany Web: www.clemco-international.com
OWNER´S MANUAL
Suction Blast Cabinet
Pulsar II
with automatic pulse cleaning
of the dust collector cartridge

2
Table of contents
1Scope of manual..........................................................................................................4
2Application and restrictions........................................................................................4
3General description.....................................................................................................5
3.1 Dimensions......................................................................................................................5
3.2 Components....................................................................................................................6
3.3 Cabinet.............................................................................................................................6
3.3.1 Cabinet lighting.............................................................................................................................. 6
3.3.2 Door............................................................................................................................................... 6
3.3.3 Gloves............................................................................................................................................ 6
3.4 Cyclone............................................................................................................................6
3.5 Dust collector cartridge..................................................................................................6
3.6 Operation facilities..........................................................................................................7
3.7 Blow-off nozzle – solid rubber........................................................................................7
3.8 Control unit and safety devices .....................................................................................7
3.9 How the system works....................................................................................................7
4Installation....................................................................................................................8
4.1 Requirements..................................................................................................................8
4.2 Set-up for initial installation or reinstallation................................................................8
4.3 Daily set-up....................................................................................................................10
4.4 Operation.......................................................................................................................11
4.5 Shut-down......................................................................................................................11
4.6 Shut down when moving the cabinet...........................................................................11
4.7 Special procedures.......................................................................................................12
4.7.1 Adjust media and air mixture....................................................................................................... 12
4.7.2 Adjustment of air jet for BNP-gun................................................................................................ 12
4.7.3 Static pressure adjustment.......................................................................................................... 13
4.7.4 Removing media.......................................................................................................................... 13
4.7.5 Dust collector cartridge cleaning / replacement of cartridge ....................................................... 14
4.7.6 Window Replacement.................................................................................................................. 14
4.7.7 Back fitting rubber curtain in case of using abrasive blasting media .......................................... 15

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4.7.8 Back fitting cyclone wear plate in case of using abrasive blast media........................................ 15
4.7.9Cartridge Pulsing Timing and Pressure....................................................................................... 15
5Maintenance...............................................................................................................16
5.1 General...........................................................................................................................16
5.2 Daily Check List ............................................................................................................16
5.3 Weekly Check List.........................................................................................................16
5.4 Monthly Check List .......................................................................................................16
6Trouble-shooting .......................................................................................................17
7Replacement parts.....................................................................................................20
7.1 Individual replacement parts for cabinet.....................................................................20
7.2 BNP-Injection gun.........................................................................................................24
7.3 Air distribution ..............................................................................................................25
7.4 Foot pedal......................................................................................................................25
7.5 Cyclone..........................................................................................................................26
7.6 Cartridge filter part no.100974 – Pulsar II....................................................................27
8Cabinet wiring 400V, 0,55kW.....................................................................................28
9Residual hazards and protective agents .................................................................30
9.1 Noise level .....................................................................................................................30
9.2 Dust exposure...............................................................................................................30
9.3 Protection of unintended blasting ...............................................................................30
9.4 Escape of accelerated blast medium from worn parts...............................................30
10 Shipping / handling of goods....................................................................................30

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1 Scope of manual
This manual covers set-up, operation and maintenance of the Suction Blast Cabinets Pulsar II.
2 Application and restrictions
Pulsar Suction Cabinets are designed to utilize most blast media < 0,8mm. There are additional require-
ments as stated below:
−STEEL:
Metallic media may require additional modifications, which must be reconfirmed with the manufac-
turer
−ALUMINIUM OXIDE:
Aluminium oxide, silicon carbide and garnet are extremely aggressive blast media that may acceler-
ate wear. When using these blast media the most exposed parts of the cabinet should be equipped
with wear resistant materials and boron carbide nozzles. (See optional accessories in chapter 7.1).
−GLASS BEADS:
Most beads are treated to ensure free flow operation even under moderate to high humidity. Glass
beads subjected to excessive moisture may clump and therefore the compressed air must be dry
(the use of an after cooler is recommended). They may be reused after thorough drying and breaking
up of the clumps.
−FINE MESH MEDIA:
When using media finer than 60µm (240 mesh) a special cyclonee is recommended, so that an ex-
treme loss of media can be avoided. The same is valid when using light weight media like plastic or
other organic abrasives (nut-shells, starch).
The cabinets and controls are designed for a maximum working pressure of 7bars. Higher working pres-
sures only for special designs. Pulsar II cabinets are designed for discontinuous blasting activities (because
of cartridge filter size). A trouble-free operation can only be guaranteed if:
⇒original parts from Clemco / Zero are used.
⇒the equipment is compatible and designed according to the operating conditions
⇒the blast cabinet is operated and maintained according to our instructions.

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3 General description
Picture 1: Pulsar II Injection blast cabinet
No.:
Description
-
Cabinet Pulsar II
1
Lamp
2
Glass window
3
Window gasket
4
Filler strip
5
Valve (door interlock)
6
Valve ( door interlock )
7
Filter with dust container
9
Door opener
10
Suction hose Ø 100mm / 4“
11
Clamp Ø 100mm / 4“
12
E-box Pulsar II
13
Safety stop
14
Push button (green)
15
Push button (rot)
16
Handholerubber
17
Foot pedal
3.1 Dimensions
-Complete unit (cabinet, cyclonee and filter): ca. 960 x 1100 x 1750mm
-Working chamber size (width x depth x height): ca. 910 x 500 x 540/950mm

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3.2 Components
"Pulsar II" – Cabinets consists of following parts:
-Cabinet Pulsar II
-Cyclonee
-Cartridge dust collector
-Control units, air lines and control box assembly
3.3 Cabinet
-Dust insulated cabinet
-Stable metal sheet construction
-White, reflecting colouring inside
-Height adjustable operator can sit or stand during blasting
-Viewing glass (safety glass), 320 x 500mm, inside with Mylar lens
3.3.1 Cabinet lighting
Mounted outside, wear free, 2 x 20 Watt, 230V.
3.3.2 Door
-Door on the right side, dust insulated enclosed
-Measurement: width x height: ca. 450 x 500/900
-Door safety interlock that interrupt blasting if door is opened
3.3.3 Gloves
-Star loop rubber for simply engage in the cabinet
-Special gloves, abrasion resistant, antistatic, coated inside with material
3.4 Cyclone
-Blast media, dust and debris from the cabinet are drawn into the cyclone for separation. Dust and
fines are first separated from the reusable blast media, which is screened of oversize particles and
later held in the storage hopper for reuse. Dust and debris are then carried into the dust collector
which traps the dust.
-Magnet in the cyclone screen
-Advantage : High blasting performance , continuous result on surface, low media consumption, dust
closed system
3.5 Dust collector cartridge
-With detachable blower top for quick replacing of the cartridges.
-Automatic jet cleaning with caster
-0,55kW-motor ca. 8m³/min fan capacity
-Filter cartridge:

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- Filter area 7m²
- Compound 80% Cellulose – 20% Polyester
- Application category after BIA USGC Test certificate 199823811 / 6210
- Very simple removal of dust from the dust container.
3.6 Operation facilities
-ON/OFF pushbutton for working chamber lighting and cartridge filter / cyclone
-Foot pedal for starting and interrupting the blast process.
-Pilot regulator for adjusting working pressure from 1,5 to 7bar.
3.7 Blow-off nozzle – solid rubber
Nozzle for cleaning blasted parts of dust.
3.8 Control unit and safety devices
−On/Off switch for cabinet lighting and motor
−Safety stop button
−Foot pedal for starting and interrupting the blast process
−Pilot regulator with gauge to adjust working pressure
−Door safety interlock that interrupt blasting if either door is opened
−Timer (J Control Switch) for triggering the automatic cleaning pulse for the dust collector
cartridge
3.9 How the system works
When air supply is on, air enters the system through a moisture separator and is guided to the main pressure
regulator. The working pressure can be adjusted with a pilot regulator.
After pushing start button:
-light will switch on
-magnet valve in e-box starts
-impulse for jet cleaning of filter cartridge is activated
Each time the foot pedal is depressed the compressed air will be supplied through the pressure regulator to
the suction gun and blast media is sucked from the hopper section of the cyclone
Blast media, debris and dust drop into the cabinet hopper and are drawn into the cyclone. Reusable heavy
blast media is separated through centrifugal force and drops into the cyclone hopper. Dust and fines are
exhausted into the dust collector cartridge. Bigger dust particles drop into the dust container and fines are
caught up by the filter cartridge. The filter cartridge is cleaned through a pulse of compressed air.
When the foot pedal is released, the blast process stops.
Therefore the circuit is closed. Door interlocks interrupt the blast process when the cabinet doors are
opened.

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4 Installation
4.1 Requirements
⇒Closed room with normal working conditions (temperature > 15°C, relative humidity < 85%).
⇒Solid level site.
⇒Sufficient space for loading parts
−Behind the cabinet minimum 80cm are necessary for emptying the dust container.
−In front of the cabinet minimum 80cm for the operator.
⇒Ensure sufficient illumination, even behind the cabinet.
⇒Electrical service:
−400V 3-phase, capacity 0,55kW
−16 socket (CEE socket)
⇒Air requirements see table 1.
orifice [mm] Nozzle
Nr. Air requirement [m3/min.] at Working pressure [bar]
Air jet Blast nozzle 3 5,5 7
3,2 6,0 4 0,4 0,6 0,75
4,0 8,0 5 0,6 0,9 1,25
Table 1 Air requirements versus nozzle size and pressure.
4.2 Set-up for initial installation or reinstallation
When shipped, standard cabinets are ready for operation, thus only the following has to be done.
(1) Place the cabinet. See also section 4.1 Requirements.
(2) Install an air supply. −Check pressure at compressed air supply. If pressure is >
7 bar, install
both an additional pressure regulator and a pressure relief valve (adapted
to air supply) between cabinet and air supply as the standard cabinet is
designed for a maximum pressure of 7 bars.
−Attach an air hose with corresponding length and diameter on air supply.
−Carefully open the air supply (hold hose tight) to blow debris and moisture
out of the attached hose.
−Close air-supply.
−Attach air hose on cabinet (coupling on the rear side of the cabinet)
−Adjust pressure regulator (rear side) for the dust collector cartridge clean-
ing pulse at 5 bars.
(3) Install electrical connec-
tion and earth screw.
If the plug is not used for the electrical connection or there is no plug, then
the work must be performed by a qualified licensed electrician.

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On the back-side of the cabinet is an earth screw. The connections have to be done
depending on the local conditions.
Ground wire, possible ground plates etc, are not part of the delivery.
(4) Test without blast media
(for transport damages).
−Close the doors.
−Press the green switch on the black box. The light must switch on and the
motor start.
−Check if motor rotates in direction of the arrow. If not, reverse polarity of
the electrical connection by a qualified electrician.
−When the light and the motor are switched on (green button), the cleaning
pulse for the dust collector cartridge can be heard in regular intervals (of
40s).
−Pick up nozzle (gloves) and depress the foot pedal. The blast process
must start (air comes out the nozzle).
−While the foot pedal is depressed, a second person opens first the right
and then the left door. At the same time the blast process should automat-
ically be interrupted (see door interlock adjustment in figure 3).
−The blast process has to be interrupted by
pushing the emergency stop
button.
−If no troubles occur, the cabinet can be tested with blast media. Otherwise
go to section 6 for trouble-shooting.
(5) Fill in blast media. −When using clean blast media fill through cyclone access door.
−If it is not
sure that blast media is really clean, turn on motor (green
switch) and slowly fill blast media into the cabinet hopper.
−Blast media will be cleaned during suction process.
−To ensure a continuous operation and to prevent agglomeration of usable
blast media in dust collector during suction, the following minimum quanti-
ties are required:
⇒Pulsar II 5 litre
(6) Test with blast media −Close the doors.
−Adjust desired blast pressure.
−Pick up gun (gloves) and start blasting by depressing the foot pedal. Di-
rect nozzle to grating.
−During the blast process a second person checks for leaks (dust).
⇒Doors.

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⇒Suction hose connections between cabinet hopper and cyclone
,
and between cyclone and dust collector.
⇒
Hose connections between filter and dust container. Tightness
can only be checked during cleaning process.
⇒Check of safety stop button
If no troubles occur, regular work can begin. /See chapter 4.4)
Picture 2: Door Safety Interlocks.
No:
Description
1
Door safety interlock
2
Nut for screw adjusting
3
Actuating screw for safety interlock
4
Door of cabinet
4.3 Daily set-up
Not necessary if an initial installation or reinstallation was performed.
(1) Daily check-up. −Cabinet view window.
−Cyclone.
−Dust container.
−BNP gun parts ( nozzle , gaskets )
(see section 5.2 Daily check list).
(2) Open air supply.
(3) Turn on lights and motor (green button).

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4.4 Operation
(1) Load parts to be blasted into the cabinet.
(2) Close the doors.
(3) Adjust the desired blast pressure.
(4) Take blast gun
in your hands
(wear gloves) and step on the foot
pedal Than the blast process will
be started
−Smooth continuous blasting is more effective than abrupt move-
ments with the nozzle.
−The rule:
„Higher pressure equals higher productivity and lower
costs“ is not valid in every situation. Exceptions are:
⇒High pressure (> 7 bar for special designs) leads to opera-
tor fatigue (more breaks are necessary).
⇒High pressure could lead to premature wear of blast me-
dia and consequently to higher costs or even to damages
of the parts.
−Distance between the nozzle and the part depends on a couple of
factors. In many cases a distance of 100 to 200 mm is the most
effective.
−The correct relation between air and blas
t media is very important
for efficient blasting (see section 4.7.1 Air / blast media mixture).
−Adjust static pressure (see section 4.7.3).
(5) When finished clean parts with blow-off nozzle and remove it from the cabinet.
(6) Regularly empty dust container. −Turn off motor and lights (red switch).
−Carefully open cover of the dust container, take out the dust bag
and dump contents into a suitable disposal container.
WARNING ! If hazardous or toxic materials have been blasted,
the debris must be specially treated!
4.5 Shut-down
(1) Turn off motor and lights (red switch) and close air supply.
4.6 Shut down when moving the cabinet
(1) If work is interrupted for a longer period of time or the cabinet is transported at higher air humidity or at
temperatures below 10 °C, blast media should be removed completely (see section 4.7.4).
(2) Disconnect plug.
(3) Disconnect air supply line.

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4.7 Special procedures
4.7.1 Adjust media and air mixture
We recommend doing the adjustment with 2 people.
Picture 3: metering valve for media – air - mixture
Pos. Nr.:
Art. Nr.
description
1
100790
Adjustment knob for metering valve ZERO
2
100791
Counter nut for metering valve
3
100789
body
4.7.2 Adjustment of air jet for BNP-gun
(1) mount correct combination of air jet
and blast nozzle −see Table.
−A worn blast nozzle influences the correct setting.
(2) screw air jet into the gun body. −Behind the counter nut about 3,5 to 4 full thread-
turn should
be seen (distance „a“ on „picture 4 adjustment of air jet“).

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picture 4: adjustment of air jet
orifice [mm]
Air jet Blast nozzle
3,2 6,0
4,0 8,0
4.7.3 Static pressure adjustment
If the static pressure in the cabinet is too low, visibility during blasting is poor and media cleaning ineffective.
If it is too high, there is good visibility, but also high media consumption because a lot of usable media is
carried into the dust collector. Proper pressure depends on type and size of media. Coarser media needs
higher, finer media needs lower static pressure.
If there is no experience in static pressure adjustment, the standard settings should be modified only after
some hours of blasting. Therefore adjust sliding damper backside the cabinet as follows:
(1) Poor visibility. Open the sliding damper 5 mm (increase static pressure, difference
to external pressure will decrease).
(2) Usable media in the dust container. Close the sliding damper 5 mm (static pressure decreases,
under
pressure increases, which leads to difficulties in opening the door).
4.7.4 Removing media
(1) Switch motor and lights on (green switch).
(2) Use blow off nozzle at closed doors and blow all media and dust out of all corners in cabinet
(3) Put a drum below the cyclone and open the plastic nut with a 22- flat wrench.
(4) Media flows out of the cyclone, in case of blockage open the man door in the cyclone and push media out
Closed cyclone door

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4.7.5 Dust collector cartridge cleaning / replacement of cartridge
(1) Empty the dust container
- Disconnect electrical (red switch) supply und pull
the plug, in order to interrupt the backlash pulse
- Unscrew the dust container and empty the content
in the special disposal container
- Attention! If there were blasted hazardous or
insalubrious materials, the dust should be
disposed as hazardous waste!
(2) Dismounting the filter cartridge
- Disconnect air supply
- Take off the fan housing
- Unscrew the screw on the flange of the filter car-
tridge and take out the filter cartridge.
(3) Mounting the filter cartridge
- Clean all reusable parts
- Put in a new filter cartridge and fasten
- Put on filter housing and fix with clamps
- Clean dust drum
4.7.6 Window Replacement
Figure 7 Filler strip
Nr.
Description
1
Filler strip
2
Molding
3
Place for filler strip
4
Cabinet wall (fits into narow slit)
5
Window tool
6
Filler strip
7
Window (fits into the expanded slit)

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(1) Pull the filler strip from the window moulding.
(2) Push the window (from the cabinet inside) through the door opening from the back to remove from the
front.
(3) Install a new window moulding in the window opening. This must be done with the filler strip channel fac-
ing the front of the cabinet.
(4) Install the view window into the slit of the moulding from the front side.
(5) Thread the strip into the installation tool and pull it. At the same time pay attention that the end of the strip
and the end of the moulding are not overlapped.
4.7.7 Back fitting rubber curtain in case of using abrasive blasting media
(1) Position the rubber curtains to mark the holes in the cabinet wall.
(2) Bore 4,5 mm holes.
(3) Fix the hooks into the holes and hang up rubber curtain.
4.7.8 Back fitting cyclone wear plate in case of using abrasive blast media
(1) Remove cyclone from cabinet.
(2) Remove cyclone inlet plate and pipe.
(3) Angle the wear plate into the cyclone inlet until it is in position with the straight end at the cyclone inlet.
(4) Pry the wear plate against the inner wall of the cyclone by using a board.
(5) Install screws into the previously bored holes to fix the wear plate.
4.7.9 Cartridge Pulsing Timing and Pressure
Pressure = 5 bar
Pulsing can also be performed at a pressure > 5 bar, but this results in more wear.

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5 Maintenance
5.1 General
During operation the cabinets 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. The following check list was
made for a 6 hour full operation. 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) View Window. −Check cover lenses for frosting.
−Replace window glass if it is damaged.
(2) Cyclone. −Clean screen when motor is switched off (several times a day
for
huge amounts of debris).
−Clean screen magnet.
(3) Dust container. Empty dust container (several times a day for huge amounts of dust).
5.3 Weekly Check List
(1) blast gun and nozzle Check nozzle gasket and replace if needed
(2) Moisture separator. Remove and check the filter element. If necessary clean filter and sight
glass with soap and warm water and dry it with compressed air. (Im-
portant - Use only smooth detergent)
A dirty filter causes loss of pressure in the system!
(2) Air hoses and blast hoses. −
Check all couplings and screws for wear or breakage and replace
them if necessary.
−Check the blast hose by hand for soft spots (reduced wall thickness)
and replace it immediately when soft spots are detected.
−Check air line (air supply) and replace it when it is worn.
−Check gaskets of couplings for wear and replace them if necessary.
5.4 Monthly Check List
(1) Cabinet door gasket. Check for leaks and wear. Replace if necessary
(2) Gloves. Check gloves for wear. When using aggressive blast media usually more
checks are necessary.
(3) Cartridge. The cartridge should be checked or replaced every three months.

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6 Trouble-shooting
Problem Probable cause Remedy
(1) Poor visibility. The motor does not rotate. Check and repair it.
Clocked cartridge. −Clean cartridge.
−Replace cartridge (see section 4.7.4).
The motor rotates in the wrong
direction.
Check if it rotates in the direction of the arrow. If
not reverse polarity of the electrical connection
(only through licensed electrician).
Blast media breaks down rapidly
and develops dust.
−Check for different blast media more suita-
ble.
−Check for lower working pressure.
Blocked suction hose between
cabinet and cyclone.
Check and if necessary disconnect hose and
remove debris and media.
Warning! The blockage is not the real cause.
Negative pressure. The following components should be checked
for leaks or wear:
−Cyclone door.
−Suction hose connections between cabinet
hopper and cyclone and between cyclone
and dust collector.
−Suction hoses for wear.
−Gasket on filter door.
(2) Abnormally high
media consumption.
Incorrectly adjusted static pres-
sure in the cabinet.
Increase static pressure with damper on top of
cabinet (see section 4.7.2).
Cyclone door open or leaking Check and replace gasket if necessary
Dust drum at filter leaks - Check gasket and replace if necessary
- check hose between dust drum and filter for
leakage and replace gasket in case
Use of too fine or light media Assembly an optional vortex cylinder
(3) Poor cleaning rate. Incorrectly adjusted metering
valve.
Improve metering (see section 4.7.1).
Blockage in air hose or gun −Press nozzle against an elastic item e.g.

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rubber plate and press foot pedal
−Dismantle hose and gun and clean
−Check for reason of blockage
−Missing or filled screen in cyclone
−Wrongly adjusted metering valve
−Too heavy media
Reduced air pressure. −Check air supply.
−If the pressure indicated on the gauge (black
box) decreases during blasting, the following
components should be checked for wear,
malfunction or contamination:
⇒Moisture separator.
⇒Pressure regulator.
⇒Air lines
Worn nozzle. Check for wear and replace if necessary.
Moist blast media.
Frequent bridging in the metering valve can be
caused by moist blast media. The reasons can
be:
⇒Cabinet was filled with moist blast
media.
⇒Humidity from air supply.
⇒Perspiration water through sharp
drop in room temperature.
Depending on cause, the following measures
are necessary:
⇒Remove moist media.
⇒Remove cause for humid air supply.
⇒Make sure, that there is not too
much temperature fluctuation.
Gun is not correct adjusted −Re-adjust gun
(4) Dust comes out the
blower.
Dust filter gasket defective. −Remove cartridge (see section 4.7.4).
−Check gasket and replace if necessary.
Defective cartridge. −Remove cartridge (see section 4.7.4).

19
−Check cartridge for cracks or similar damag-
es and replace if necessary.
(5) Static shocks. Cabinet not grounded. Ground cabinet.
(6) No air and no media
come out the gun
Door interlocks are not actuat-
ed.
Adjust over-travel stop and screw of the door
interlocks (see figure 4).
Blocked blast hose.
−Turn out nozzle and check for blockage.
−Check blast hose for blockage. .
Warning! The blockage is not the cause.
The cause could be:
⇒Missing or overfilled screen in the
cyclone.
⇒Incorrectly adjusted metering valve.
⇒Too heavy blast media.
Blocked moisture separator. Clean moisture separator (see section 5.3).
(7) Air only (no media)
comes out the noz-
zle.
No blast media in the blast sys-
tem
- refill
Moist media prevents flow. −Remove moist media.
−Remove cause for humid air supply.
(8) Irregular flow or too
much blast media
comes out of nozzle.
Incorrectly adjusted metering
valve.
Adjust new (see section 4.7.1).
Choke valve not completely
opened.
Open choke valve completely.
(9) No interruption of
blast process when
foot pedal is re-
leased.
Foot pedal valve blocked. Replace valve.
Incorrectly connected air hoses
on the foot pedal.
Connect air hoses correctly (see cabinet plumb-
ing).

20
7 Replacement parts
7.1 Individual replacement parts for cabinet