Clemco SCW-2048 User manual

Revision: 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
Single Chamber Blast Machine
for 1 Operator
with manual or pneumatic
media metering valve

2
YOUR BLAST MACHINE
Standard Pneumatically
operated media
metering valve
Electric remote
controls
Dual function
pneumatic
Dual function
electric
TABLE OF CONTENTS
1SCOPE OF MANUAL ...........................................................................................4
2APPLICATION AND RESTRICTIONS..................................................................5
3GENERAL DESCRIPTION....................................................................................5
3.1 STANDARD BLAST MACHINE..........................................................................................5
3.1.1 How the system works........................................................................................................6
3.1.2 How the pneumatic remote control works ..........................................................................6
3.2 BLAST MACHINE WITH PNEUMATICALLY OPERATED MEDIA METERING VALVE.....................7
3.3 OPTIONAL ELECTRIC REMOTE CONTROLS......................................................................8
3.4 OPTIONAL REMOTE CONTROL WITH DUAL FUNCTION......................................................8
3.4.1 Dual function pneumatic.....................................................................................................9
3.4.2 Dual function electro-pneumatic.......................................................................................10
3.5 OPTIONAL SINGLE CHAMBER BLAST MACHINE WITH PNEUMATIC METERING VALVE,
COMPRESSED AIR REGULATOR GOVERNED BY PILOT AIR AND RMS REMOTE CONTROL VALVE ..10
3.5.1 RMS 2000 or RMS 500 + RMS 1500 pneumatic remote control and remote control
valves 10
3.5.2 Pneumatic remote control with dual function and RMS 2000 remote control valve.........12
4QUICK STOP SYSTEM (ACCESSORIES).........................................................12
5SET-UP AND OPERATION ................................................................................14
5.1 REQUIREMENTS ........................................................................................................14
5.2 SET-UP FOR INITIAL INSTALLATION OR REINSTALLATION ...............................................14
5.3 DAILY SET-UP............................................................................................................16
5.4 OPERATION ..............................................................................................................16
5.5 SHUT-DOWN .............................................................................................................17
5.6 SHUT-DOWN WHEN MOVING EQUIPMENT .....................................................................17
6MAINTENANCE..................................................................................................17
6.1 GENERAL..................................................................................................................17

3
6.2 DAILY CHECK LIST .....................................................................................................17
6.3 WEEKLY CHECK LIST..................................................................................................17
6.4 MONTHLY CHECK LIST................................................................................................18
7TROUBLE-SHOOTING.......................................................................................18
8REPLACEMENT PARTS....................................................................................20
8.1 BLAST MACHINES 1440 –2460..................................................................................21
8.2 BLAST MACHINES MIGHTY MITE .................................................................................23
8.3 ELECTRIC PANEL RME-1 /-2......................................................................................23

4
1 Scope of manual
This manual covers operation and maintenance for the following single chamber blast machines with
pneumatic or electric remote controls and manually or pneumatically operated media metering valves:
Volumina
[l]
Model Max. pressure [bar] Remote Control Valve Metering valve
When using
RME RMS-2000A
(RMS 1500+500)
RMM-50A pneumat. manual
20 1028 10 - - 
40 1628 10 - - 
50 1440 12 10 - 
60 1638 12 10 - - 
100 1648 12 10 - 
100 2040 12 10 - 
140 2048 12 10 - 
200 2452 12 10 - 
300 2460 12 10 - 
Table 1: Scope.
FSV, QK-Quantum, MP ½”, = manually operated abrasive metering valves
PT = pneumatically operated abrasive metering valve
Additionally the following Owner’s manuals should be considered:
−Remote control valve RMS-2000, 1500, 500
−Owner’s manual of the metering valve

5
2 Application and restrictions
Single chamber blast machines can be used with all types of abrasive (60 – degree conical bottom for
fine mesh abrasive on option). Table 1 shows the maximum working pressure for the different
models available. Higher working pressure is possible only for special designs.
The following options are recommended:
−Electric remote controls for very long blast hoses.
−Dual function (pneumatic or electric) to blow-off parts after blasting.
3 General description
3.1 Standard blast machine
The standard blast machine is equipped with pneumatic remote controls and a manually operated
media metering valve.
Figure 1: Standard blast machine.

6
Figure 1 shows the major components of the standard blast machine:
•Pot with
−remote control valve RMS-2000A (RMS 1500+500) or RMM-50A (item 2).
−muffler (item 5).
−moisture separator (item 4).
−media metering valve (item 3) manually or pneumatically operated.
−choke valve (item 7).
•Deadman handle (item 6) with twinline hose (item 11).
•Blast hose with nozzle holder and nozzle (item 8 and 9).
3.1.1 How the system works
When the blast machine is connected to an air supply (compressor), the airflow passes through the
moisture separator (item 4) to the remote control valve RMS-2000A or RMM-50A (item 2). When the
deadman handle (item 6) is depressed, the pop-up valve (item 10) seals off the filling port with the
pop-up gasket (item 12) and the blast pot (item 1) is pressurized. The abrasive metering valve (item 3)
controls the flow of abrasive into the air stream.
With the blast hose (item 8) the abrasive is guided to the nozzle (item 9). When the operator releases
the deadman handle or the pet cock is opened, the blast process stops and the pot is depressurized.
3.1.2 How the pneumatic remote control works
The remote control enables the operator to start or interrupt blasting from a remote position and is a
safety equipment to prevent accidents. Each blast machine must be equipped with remote
control!
The pneumatic remote control consists of a remote control valve RMS-2000A or RMM-50A (item
2), a deadman handle (item 6) and a twinline hose (item 11). The brown remote control hose guides
compressed air from the remote control valve to the deadman handle. When the deadman handle is
depressed, the air passes from the brown to the yellow hose and is guided back to the remote control
valve. The pot is pressurized and the blast process starts. When the deadman handle is released the
blast process stops (the pot is depressurized).
For a more detailed description how the remote control valve RMS-2000 (RMS 1500+500) or RMM-
50A works, read the included Owner’s manual.

7
3.2 Blast machine with pneumatically operated media metering valve
Figure 2: Blast machine with pneumatically operated metering valve and pneumatic remote controls.
Principle of operation: same as the standard pressure blasting device.
When the deadman handle (item 6) is depressed the metering valve opens, when it is released, the
metering valve closes. Read the Owner’s manual for more information on the metering valve.

8
3.3 Optional electric remote controls
Figure 3: Electric remote controls and pneumatically or manually operated abrasive metering valve.
In order to reduce the time to stop blasting (especially when using longer blast hoses), the twinline
hose between the deadman handle and the remote control valve is replaced by an electric cord
(orange) and the electric panel RME-1 (item 15). The magnetic valve converts the electric signal into
a pneumatic signal.
3.4 Optional remote control with dual function
This option can only be applied with pneumatically operated media metering valves and is
especially recommended for very long blast hoses and to blow off the blasted surface with
compressed air.
An additional switch on the deadman handle enables the operator to open or close the pneumatically
operated media metering valve during blasting (deadman handle depressed).

9
3.4.1 Dual function pneumatic
An additional 3-way slide valve (pos. 6.1) enables the operator to open or close the metering valve
when the deadman handle is depressed. When the slide of the 3-way valve is moved to the left the
abrasive metering valve opens, to the right it is closed again. When the deadman handle is released
the media metering valve closes independent of the slide position.
Figure 4: Dual function pneumatic.

10
3.4.2 Dual function electro-pneumatic
Figure 5: Dual function electric.
An additional electrical switch on the deadman handle enables the operator to open or close the
pneumatically operated metering valve when the deadman handle is depressed. A magnetic valve
mounted on the electric control panel RME-2 (item 15) converts the electric signal into a pneumatic
signal. When the deadman handle is released the media metering valve closes independent of
the switch position.
3.5 Optional single chamber blast machine with pneumatic metering valve,
compressed air regulator governed by pilot air and RMS remote control valve
3.5.1 RMS 2000 or RMS 500 + RMS 1500 pneumatic remote control and remote
control valves
Fig. A

11
Principle of operation:
Compressed air is supplied to the system via a HMS water separator (item 4). The air is fed into the
RMS 2000 remote control valve (item 2) and from there via the port 2A (brown remote control hose)
- to the deadman handle (item 6)
- and to the pressure regulator (1/4" item 30) and the 2/3 way valve (item 32).
When the deadman handle is depressed, the compressed air is fed through the yellow remote control
hose
- to the remote control valve port 2B (item 2)
- to the blast media metering valve (item 3) which opens
- and to the regulator governed by pilot air (item 31).
This causes the blast machine to become pressurised, and the blasting process starts.
The desired blasting pressure can be set at the pressure regulator item 30.
When the deadman handle is released, the air pressure ceases to be supplied via the yellow remote
control hose to the remote control valve, so that:
- the RMS 2000 (item 2) is no longer pressurised
- the blast machine is no longer pressurised
- the blast media metering valve (3) closes
- the 3/2 way valve (32) closes
A detailed description of the method of operation of the blast media metering valve used can be found
in the metering valve manual supplied.
Options:
- Splitting the RMS 2000 remote control valve into the
oRMS 1500 inlet valve
oRMS 500 outlet valve
- Additional safety valve (size to be specified by the customer)
- Dual function deadman handle; this allows
othe blast media metering valve to be opened and closed whilst the deadman handle
is depressed
oto blast with air only, for instance when cleaning

12
3.5.2 Pneumatic remote control with dual function and RMS 2000 remote control valve
Bild - B
Principle of operation:
A slide valve is fitted to the deadman handle (item 6), which allows the operator to open and close the
blast media metering valve (blast media feed On/Off) whilst the deadman handle is depressed (item
6). When the slide is moved to the left, the metering valve opens; when it is moved to the right, it
closes again. When the deadman handle is released, the pneumatic metering valve closes, and the
blast media feed stops irrespective of the position of the slide valve.
4 Quick Stop System (accessories)
The Quick Stop System SSAS1 is offered in order to reduce the time normally necessary to stop
blasting (between 2 and 15 seconds) to less than 1 second.
German law demands this equipment.
CLEMCO recommends to use a Quick Stop System for the following applications in other countries:
•Blast pressure ≥ 5 bar
•Length of blast hose ≥ 20 m
•Hard structure abrasive like steel grit
Stock Nr. 90777D Quick Stop System SSAS1

13
Figure 6: Quick Stop System SSAS1
Legend:
1 Blast pot with:
- 2 Remote Control (example RMS 2000)
- 3 Abrasive metering valve
- 4 Non return valve
5 Abrasive hose between pot and SSAS1
6 Control hose
7 Abrasive hose between SSAS and nozzle (max. 10 m)
8 Nozzle holder with nozzle
9 Electric remote control handle and control cord RLX-E
10 Quick stop system SSAS with:
- 11 Dust container
- 12 Muffler
- 13 Air balance buffer
- 14 Electric control box
- 15 4/2 way valve
- 16 Pneumatic valve (closed during blast operation)
- 17 Pneumatic valve (open during blast operation)
- 18 Frame

14
5 Set-up and operation
5.1 Requirements
For a proper function of the blast machine, a sufficient air supply is necessary (see table 2).
Nozzle
size [mm]
Air consumption [m3/min.]
Pressure at the nozzle [bar]
6 8 10 12
6.5 2.0 2.6 3.2 4.7
8 3.4 4.8 5.4 6.4
9.5 4.8 6.2 7.6 9.0
11 6.4 8.3 10.1 12.0
12.5 8.4 10.7 13.1 15.4
Table 2: Air consumption
5.2 Set-up for initial installation or reinstallation
(1)Place blast machine.
On an even and firm ground.
(2) Install an air supply for working
pressure indicated on pot. −Place compressor upwind near blast machine (
no
contaminated air should enter compressor).
−Start compressor and bring it up to operating temperature (5
to 10min.). Only use compressors whose rating does
not
exceed the maximum working pressure of the pot!
−Attach airline
(appropriate dimension) with all necessary
gaskets in place to air outlet of compressor and safety lock
couplings.
Escaping air is dangerous and lowers
efficiency!
−Carefully open air valve of compressor to blow debris and
moisture out of attached airline.
−Close air valve.
−
Install an appropriate coupling to air inlet of blast machine
(safety coupling).
−Connect airline to blast machine and safety lock it.
−For trouble free blasting we recommend an air supply free of
oil and water (air cooler with cyclone and automatic drain).
(3) Attach blast hose and nozzle to
blast machine. −Check gasket of coupling for wear.
−Connect blast hoses to length needed (All gaskets
must be
in place!), attach them to blast machine and safety lock them.
−Choose an appropriate nozzle and attach it to nozzle holder
(with a gasket).
(4) Install a deadman handle and
−Pneumatic remote control:

15
remote control hoses
(pneumatic controls) or an
electric cord and the electric
panel RME (electric remote
controls).
⇒
Connect twinline hose (yellow/brown) to
corresponding
twinline hose (yellow/brown) coming
from remote control valve RMS-2000A or RMM 50A.
⇒
Connect yellow and brown remote control hose to
corresponding yellow and brown nipples of deadman
handle.
Warning!
A reversed connection of remote control hoses
causes malfunction and danger of injuries!
−Electric remote controls:
⇒Connect extension cord to plugs on deadman handle
and electric panel RME.
⇒
Connect electric panel RME to remote control hoses
coming from remo
te control valve (corresponding
colours of nipple).
−With two nylon ties band deadman handle to blast hose just
behind nozzle holder.
−Every 1,5m band twinline hose or electric cord to blast hose
(sufficient freedom of movement, because under pressure
blast hose expands).
(5) Put on protective equipment. −Abrasive-resistant clothing.
−Airfed helmet with connection to breathing air supply (air filter)
and adjustment of air volume with an air control valve attached
to belt.
−Leather gloves and safety shoes.
−Ear protection.
(6) Check moisture separator,
remote control and remove
moisture from blast machine.
−Open petcock on remote control valve RMS-2000A or RMM-
50A.
−Open choke valve.
−Open abrasive metering valve fully.
−Open air valve of compressor.
−Close petcock o
n remote control valve RMS 2000A or RMM
50A while depressing deadman handle.
−A few minutes hold deadman handle depressed (pop-up valve
closes and air comes out of nozzle).
−Adjust drain of moisture separator, so that a constant stream
of liquid and air is expelled under pressure.
−Depressurize blast machine (release deadman handle or open
petcock of remote control valve).

16
5.3 Daily set-up
Not necessary if an initial installation or reinstallation was performed (see section 5.2).
(1) Air supply. Start compressor and bring it up to operating temperature
(5 to 10min.).
(2) Put on protective equipment. −Abrasive-resistant clothing.
−Airfed helmet with connection to breathing air supply (air
filter) and adjustment of air volume with an air control valve
attached to belt.
−Leather gloves and safety shoes.
−Ear protection.
(3) Check moisture separator,
remote control and remove
moisture from blast machine.
−Open petcock on remote control valve RMS-2000A or
RMM-50A.
−Open choke valve.
−Open abrasive metering valve fully.
−Open air valve of compressor.
−Close petcock on remote control valve RMS 2000A or
RMM 50A while depressing deadman handle.
−A few minutes hold deadman handle depressed (pop-
up
valve closes and air comes out of nozzle).
−Adjust drain of moisture separator, so
that a constant stream
of liquid and air is expelled under pressure.
−
Depressurize blast machine (release deadman handle or
open petcock of remote control valve).
5.4 Operation
(1)Load abrasive into blast
machine. −Close abrasive metering valve.
−Open petcock of remote control valve RMS-2000A or
RMM-50A.
−Pour abrasive into concave head of pot (filling port).
(2)Blasting. −Close petcock of remote control valve.
−Point nozzle to surface being blasted and depress deadman
handle to start blasting.
−Adjust choke valve.
−Open abrasive metering valve for proper air/abrasive blend.
−Blast until pot is nearly emptied of abrasive (
do not blast
until pot is completely empty because of higher wear).
−Proceed with (1).

17
5.5 Shut-down
(1)Empty all abrasive. Blast machine not in use > 1 day (abrasive could get moisture).
5.6 Shut-down when moving equipment
No special measures required.
6 Maintenance
6.1 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!
6.2 Daily check list
(1)Pot. −Check gasket of filling port and replace it at first sign of wear
(replacement possible from outside).
−Check pop-up valve and replace it at first sign of wear.
(2)Airline and blast hose. Check hoses for sharp bends, causing high loss of energy and
rapid wear.
No vehicles should pass over hoses!
(3)Nozzle and nozzle holder. −Check nozzle gasket and replace it at first sign of wear.
−
Check nozzle and nozzle holder (thread) for wear and
replace them if necessary.
(4)Remote control valve and
accessories. −Open petcock of remote control valve RMS 2000A or RMM
50A and check for water. If water is detected check moisture
separator (see section 5.3)
−
Check rubber button of deadman handle for wear and
replace it if necessary.
−Check fittings of remote control valve for tightness.
−
Check all electric and pneumatic connections of electric
panel RME-1 or RME-2 (electric remote controls).
6.3 Weekly check list
(1)Moisture separator. Remove and check filter element. If necessary clean filter and sight
glass with soap and warm water and dry it with compressed air.
A dirty filter causes loss of pressure in the system!
(2)Muffler.
Check for wear or blockage and clean or replace interior body.
(3)Air hoses and blast hoses. −Check all couplings and screws for wear or breakage and replace
them if necessary.
−
Check whole blast hose by hand for soft spots (reduced wall
thickness) and replace it immediately when soft spots are

18
detected.
−Check airline (air supply) and replace it when it is worn.
−
Check gaskets of couplings for wear and replace them if
necessary.
6.4 Monthly check list
(1)Remote control valve RMS-
2000A (RMS 1500+500) or
RMM-50A.
Check all fittings and connections of remote control valve for
leakage.
(2) Muffler.
Check condition of muffler and corresponding piping.
7 Trouble-shooting
Problem
Probable cause
Remedy
(1)Neither abrasive nor air
comes out of nozzle.
Air valve of compressor is
closed.
Open air valve.
Blocked moisture separator. Check and clean moisture
separator.
Remote control valve RMS-
2000A (RMS 1500+500) or
RMM-50A (item 2) doesn’t work.
Check remote control valve and
remote control hoses for loose
conn
ections while outlet valve is
closed (depressed deadman
handle).
Electric remote controls:
magnetic valve of electric panel
RME (item 15) is blocked.
Disassemble and clean it.
(2) Air but no abrasive comes
out of nozzle.
Closed abrasive metering valve.
Open abrasive metering valve.
−Moist abrasive blocks
abrasive flow at bottom of
pot.
−No screen or cover.
−Several times open and close
choke valve (item 7) rapidly.
Attention! This measure
leads to increased wear of
the rubber nipple in the
abrasive metering valve
FSV (service life <50h)
−Open inspection door and
clean pot.
−Install an after cooler for air
supply.
(3) Irregular flow of abrasive
comes out of nozzle.
Incorrectly adjusted abrasive
metering valve (item 3).
Check adjustment and open it
completely if necessary.
Clogging. −Check nozzle and gasket for
wear and replace them if
necessary.
−Open inspection plate of
metering valve and clean it.
Choke valve incorrectly
adjusted.
Correctly adjust choke valve.

19
(4) Too much abrasive comes
out of nozzle.
Abrasive metering valve too
much opened.
Check and correct adjustments.
Choke valve not completely
opened.
Check and open it completely if
necessary.
(5) Pop-up valve does not
remain closed. Insufficient air volume or
pressure. Check air pressure of compressor with a needle
gauge.
(6) Pop-up valve does not seal
off filling port after
pressurization.
Worn pop-up valve and / or
gasket (item 10). Replace pop-up valve and / or gasket.
Blocked guide for pop-up valve. Open inspection door (item 21)
and clean blast machine.
(7) Blast machine does not
depressurize or is blocked.
Clogged deadman handle. Clean deadman handle.
Remote control hose incorrectly
connected.
Exchange connections.
Remote control valve RMS-
2000A (RMS 1500+500) or
RMM-50A defective.
Disassemble and repair it.
Electric remote controls (with or
without dual function):
Switch on the magnetic valve in
position ″1“ (manual control).
Put switch in position ″0“
(automatic control).

20
8 Replacement parts
Figure 7: Replacement parts.