Diamatic BDC-SLURRY PRO User manual
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Operating Instructions
BDC-SLURRY PRO
Original Operating Instructions
Version 1.0:
Diamatic
622 Grant Rd
Folcroft, PA 19032
Tel: +1 619-295-0893
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Table of Contents
Table of Contents-------------------------------------------------------------------------------------------------------------------2
1.
Introduction-----------------------------------------------------------------------------------------------------------------------3
2.
Machine Description------------------------------------------------------------------------------------------------------------4
3.
Safety-------------------------------------------------------------------------------------------------------------------------------5
3.1 Work Area Safety ----------------------------------------------------------------------------------------------------------5
3.2 Electrical Safety ------------------------------------------------------------------------------------------------------------5
3.3Personal Safety---------------------------------------------------------------------------------------------------------------6
3.4 Machine Safety General --------------------------------------------------------------------------------------------------6
3.5 Maintenance Safety --------------------------------------------------------------------------------------------------------6
3.6 Safety Regarding Slurry Vacuums -------------------------------------------------------------------------------------7
3.8 Transport Safety ------------------------------------------------------------------------------------------------------------7
4.
Start Up and Shut Down-------------------------------------------------------------------------------------------------------8
5.
Inspection and Maintenance --------------------------------------------------------------------------------------------------9
5.1. Emptying --------------------------------------------------------------------------------------------------------------------9
5.2. Pump Cleaning Instructions------------------------------------------------------------------------------------------- 10
5.3. Filter Inspection:--------------------------------------------------------------------------------------------------------- 11
5.4. Motor Cover Disassembly for Brush Inspection ----------------------------------------------------------------- 12
5.5. Ametek Motor Brush Inspection:------------------------------------------------------------------------------------ 13
5.6. Electro Motor Brush Inspection:------------------------------------------------------------------------------------- 14
6.
Troubleshooting --------------------------------------------------------------------------------------------------------------- 15
7.
Technical Information: ------------------------------------------------------------------------------------------------------- 16
8.
Slurry Vacuum Parts Breakout:-------------------------------------------------------------------------------------------- 17
9.
Slurry Vacuum Parts List:--------------------------------------------------------------------------------------------------- 18
10.
Filter Module Parks Breakout:------------------------------------------------------------------------------------------- 19
12.
Filter Module Parts List: --------------------------------------------------------------------------------------------------- 20
13.
Rear Stack Assembly Parts Breakout: ---------------------------------------------------------------------------------- 21
14.
Rear stack Assembly Parts list:------------------------------------------------------------------------------------------- 22
16.
Slurry Collection Assembly Parts Breakout:-------------------------------------------------------------------------- 23
17.
Slurry Collection Assembly Parts List:--------------------------------------------------------------------------------- 24
18.
Slurry Deck Motor Assembly Parts Breakout:----------------------------------------------------------------------- 25
19.
Slurry Deck Motor Assembly Parts List: ------------------------------------------------------------------------------ 26
20.
Floor Tool 32” Assembly Parts Breakout:----------------------------------------------------------------------------- 27
21.
Floor Tool 32” Assembly Parts List:------------------------------------------------------------------------------------ 28
22.
Double Stack Frame Assembly Parts Breakout: --------------------------------------------------------------------- 29
23.
Double Stack Frame Assembly Parts List: ---------------------------------------------------------------------------- 30
24.
Enclosure with Switch, PVC Parts Breakout:------------------------------------------------------------------------- 31
25.
Enclosure with Switch PVC Parts List: -------------------------------------------------------------------------------- 32
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1.
Introduction
Before use, operators must be provided with information, instruction and training for the use of the machine and the substances for
which it is to be used, including the safe method of removal and disposal of the material collected. All persons who are working
with or maintaining this machine must read the manual carefully and understand it fully. In case you sell the unit, hand it on to the
next owner.
Keep this manual always with the machine, to enable it to be referred to at any time. Any other work
not covered by this operating manual must not be carried out.
This machine is designed for industrial use by professionals. Only authorized and trained personnel may operate this machine.
This machine is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of
experience and knowledge. Diamatic BV offers a course on the use of the machine in order to make the operating and maintenance
personnel familiar with all elements of the machine.
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2.
Machine Description
The BDC-SLURRY PRO is an electrically powered slurry vacuum. This 120V single phase slurry vacuum comes with two
powerful 1200W motors and .5HP return pump enabling vacuuming and pumping simultaneously. The BDC-SLURRY PRO uses a
32” floor sweeper to vacuum slurry into its 32-gallon storage container. Designed to meet OSHA silica dust compliance standards,
while providing 44ft2 of hydrophobic filtration – 99% at 0.5 microns. The BDC-SLURRY PRO is designed to be the best solution
for all slurry control needs, with removal and disposal all in one unit. The BDC-SLURRY PRO produces up to 200 CFM, strong
enough to leave the floor clean of slurry in one pass. The BDC-SLURRY PRO will speed up production by having an easier and
more reliable way to remove slurry off of a concrete surface. It can be used for wet applications only.
1
1200W Motor
4
Storage Container
7
32” Floor Sweeper
2
Return pump
5
Filter Housing
8
Blast Gate
3
Composite Modular Housing
6
Liquid fill shut off
9
Separate Slurry Collection Chamber
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3.
Safety
Read all safety warnings and all instructions. Failure to follow the warnings and instructions may
result in electric shock, fire, explosions and / or serious injuries.
3.1 Work Area Safety
a)
Do not use the machine in rain, damp or wet locations.
b)
Avoid dangerous environments: do not work in the presence of explosive atmospheres, in the presence of flammable liquids, gases or
dust. Remove materials or debris that may be ignited by sparks.
c)
The surface to be treated must be clean, make sure to remove all stones, screws etc..
Any stones, screws, bolts, pieces of wire etc. could cause serious damage if it gets inside the machine!
d)
Make sure there is enough ambient light on the work area. Cluttered or dark areas invite accidents.
e)
Do not use on wood.
f)
Keep children and bystanders away while operating the machine. They are likely not to foresee the potential dangers of the
machine. Distractions could cause you to lose control of the machine.
g)
Persons who are not operating the machine must not be permitted to stay in the surrounding area of at least 5 meters from the
machine.
h)
Never use the machine when the surface is not clear and if there is a risk of stumbling or tripping.
i)
Make sure that there are no cables or hoses in the driving direction of the machine.
j)
Make sure that there is nothing standing or situated on the surface to be treated.
k)
Make sure the machine can travel over all inequalities on the surface, small inequalities like weld seams or floor joints are no barriers
for the machine.
l)
Never stay in the rain with the machine.
m)
Check if there are any obstacles that can snag the cables when the machine is moving.
n)
Remove reinforcing steel or other objects protruding from the surface in order to prevent damage to the compounds or diamond discs.
o)
Warning!
Make sure that the surface to be treated does not contain dangerous materials such as:
-
combustible or explosive dusts or substances.
-
carcinogenic or pathogenic substances.
p)
Secure the work area around the machine in public areas providing an adequate safety distance from the machine. Use a red and
white safety chain and danger sign to enclose the work area.
3.2 Electrical Safety
a)
Use only extension cables for extending the main cable that are sized and marked in accordance with the overall power
consumption of the machine. Do not use damaged extension cables.
b)
Electrical cables must be rolled entirely off of the reels.
c)
Any damage to the electric cables and/or electrical components is not permitted.
d)
The voltage on the identification plate must comply with the power supply.
e)
Use an electrical power supply connection with earth connection and earth leakage circuit breaker.
f)
The circuit breaker of the power supply must have a ‘’D’’ characteristic. Circuit breakers with a “C” or “B” characteristic can give
problems when switching the motor on.
g)
Keep the machine original; The machine is always equipped with an earthed connection, do not change this and always use
earthed cables with an earthed plug.
h)
Inspect and test the electrical components regularly. The electrical components have to satisfy with the requirements set out in the
harmonised norm EN60204-1.
i)
Always call a skilled electrician or your distributor when you have questions about the safety of the electrical components.
j)
Work on electrical equipment or operating materials may only be undertaken by a skilled electrician or by trained persons under the
guidance and supervision of a skilled electrician as well as in accordance with the electrical engineering regulations.
k)
Always use tools that are insulated against voltages.
l)
Do not abuse the cables. Never use the cables for carrying, pulling or unplugging the machine. Keep cables away from heat, oil,
sharp edges or moving parts. Damaged or entangled cables increase the risk of electric shock.
m)
Be careful with water on the treated surface. Electrical cables must not come into contact with water.
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n)
The main power switch on the machine must be in the “Off” position before connecting to the power supply. (Only if there is a
main switch present on the electrobox.)
o)
During a long standstill of the machine, pull out the main plug and cover it with plastic foil.
p)
If the machine is to be operated using power from a generator, the generator must be operated in accordance with the current legal
regulations and directives in force. (this applies to the protective earth conductor in particular) in order to ensure that all safety
devices are functioning and to eliminate possible damage to electrical components.
3.3 Personal Safety
a)
Always wear Personal Protective Equipment while working with the machine.
-Dust mask class FFP2 or higher
-Ear protection
-Safety glasses with lateral protection
-Protecting gloves
-Safety shoes
b)
Dress properly. Do not wear loose clothing or jewelry. Keep your hair, clothing and gloves away from moving parts.
c)
Stay alert, watch what you are doing and use common sense when operating the machine.
d)
All persons in the proximity of the machine, must wear ear protectors and safety shoes.
e)
Always seek professional medical attention immediately in case of injury.
3.4 Machine Safety General
a)
Safety functions and operating functions must work correct.
b)
No loose bolts and nuts permitted.
c)
Never operate machine without the guards and/or safety devices in place.
d)
Never change anything on the safety devices on the machine!
e)
The machine, specially the handle grips must be free of fats/oils and have to be dry.
f)
If the length of the brushes is, due to wear, less than 5mm or they are extremely deformed, the brushes have to be replaced.
Check the Service Manual for the order numbers.
g)
All repair work has to be done by qualified Diamatic personnel, this guarantees a safe and reliable machine.
The part numbers can be found in the Service Manual.
h)
If safety-critical changes occur to the machine or its working method, the machine must be shut down immediately! The cause
of the fault must be established, and rectified.
i)
In the event of operational malfunctions the machine must be shut down immediately and secured!
j)
Do not use the unit when it is damaged.
k)
Do not open or remove protective guards while driving gears are running.
3.5 Maintenance Safety
a)
Pull out the main plug before starting inspections and repairing on the machine.
b)
Wait for standstill of all drives before any inspections, adjustments and/or maintenance work is started.
c)
Block the machine in a stable position before doing any maintenance work.
d)
Failures due to inadequate or incorrect maintenance may generate very high repair costs and long standstill periods of the
machine. Regular maintenance therefore is imperative.
e)
Operational safety and service life of the machine depends, among other things, on proper maintenance.
f)
Prevent premature wear by keeping the machine as dust free as possible. Clean the machine for this reason regularly with a dust
collector and non-aggressive materials. Never use a high-pressure water cleaner to clean the machine.
g)
It is advisable to stock all spare parts or wear parts that cannot be supplied quickly. As a rule, production standstill periods are
more expensive than the cost for the corresponding spare part.
h)
Do not use any aggressive cleaning materials!
i)
Use lint-free cleaning cloths!
j)
For the electrical parts, use a tool that is insulated against voltages.
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3.6 Safety Regarding Slurry Vacuums
a)
The slurry container must be emptied regularly. Comply with the local waste treatment regulations considering the removed
material.
b)
The slurry hose must be connected properly with a hose clamp and industrial tape.
c)
The slurry hose must be undamaged and free of obstructions.
d)
Always switch on the dust collector first!
3.8 Transport Safety
a)
Be aware of your surroundings and machine operating level. Do not side hill, do not run on steep incline, this could cause
machine to tip over.
b)
The weight of the BDC-SLURRY PRO is 346 lbs. Use a crane or lift when transporting the machine, use the lifting eyes of the
machine.
c)
Before every use check the lifting eyes and welds for: deformation, damages, cracks, corrosion and wear.
d)
When lifting the machine from the ground, always use the lowest lifting speed. The cables must first be tensioned at this speed; they
must not be slack when the machine is lifted from the ground.
e)
During hoisting make sure to be at a safe distance from the machine with the most optimal view on the machine and working
environment.
f)
Never stand directly below the machine.
g)
When transporting the machine do so in such a manner that damage due to the effects of the use of force or incorrect loading and
unloading is avoided.
h)
The lifting eyes can also be used to fasten the machine on a pallet or during transport.
i)
Always drive backwards when driving up to a ramp or grade, and forwards when driving of the ramp.
j)
Chock wheels for transport and keep control handle in neutral position.
k)
Don’t leave the machine unsecured on jobsites.
l)
Park the machine always on a flat horizontal and levelled surface.
m)
Make sure the floating shroud is in transport mode when you transport the machine.
n)
Make sure the electrical cable and dust hose are disconnected.
o)
Store the cleaned and dry machine in a humid free room. Protect the electrical motor from moisture, heat dust and shocks.
p)
Never use the machine for lifting persons or items.
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4.
Start Up and Shut Down
Check that the slide valve
is closed.
Connect to proper power
source as indicated on the
serial tag.
Start machine using the ON /
OFF switch on the motor
domes.
Turn machine off using the
ON / OFF switch on the motor
domes.
It is critical that you
empty/clean the vacuum
after each use. If material
is allowed to “set up”
inside it will render the
vacuum inoperable. Please
refer to Section IV for
instructions.
Machine should be
emptied after every use.
1
2
3
4
Note: Electrical installation should be performed by a qualified electrician in accordance with
governing national and local electrical codes.
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5.
Inspection and Maintenance
5.1. Emptying
Collection vessel and pump must be cleaned after every single use. The pump may be used while the vacuum is
running, but if the pump needs to be cleaned you must turn the vacuum off.
Use the internal pump to
evacuate the water.
You
must hold the switch down
to operate the pump.
If pump becomes clogged,
refer to
the pump cleaning
instruction on the next page.
Once most of the water has
been pumped out of the
machine you can open the slide
gate at the bottom of the
collection unit. The solids can
be flushed
or scooped out. Close
slide gate when finished.
Check for carryover liquid
by opening the slide gate
under the filter housing.
Close slide gate when
finished.
1
2
3
4
Note: The emptying/cleaning instructions must be performed after each use. Do not
allow the material to set up inside.
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5.2. Pump Cleaning Instructions
Loosen hose cuff.
Disconnect clamps on
either side.
Remove motor deck.
Remove the pump
from the tank without
disconnecting the hose.
Place the pump in a 5-
gallon bucket and run the
clean water through the
pump.
1
2
3
4
5
Note: Pump should be cleaned daily to ensure material doesn’t build up and harden.
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5.3. Filter Inspection:
Disconnect the pump
from power if included.
Disconnect clamps on
either side.
Remove motordeck
and inspect filter. The
filter is used to stop
moisture from
entering the motor and
not for
filtering dust.
Loosen filter hold down
bracket bolts enough to
remove the filter.
Remove filter and
inspect. Replace filter as
needed to maintain
optimal performance
Open the slidegate under
the filters to empty any
liquid from the filter
chamber.
Close the slide gate before
using the unit.
5
Note: Inspection of the filter will vary with usage of the machine.
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5.4. Motor Cover Disassembly for Brush Inspection
Turn the machine off,
then disconnect the
power source.
Disconnect motor
terminal.
Loosen the motor
retaining knobs enough
to remove motor under
negative pressure.
Remove the 6 screws
attached to each motor
assembly.
Remove the plastic
motor cover to access
the top of the motor.
Remove the 2 metal
motor-cap-retaining
clips locating on each
motor (for Ametek
motors only)
1
2
3
4
6
5
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5.5. Ametek Motor Brush Inspection:
NOTE: A motor brush should be replaced if its length is less than 0.25 inches.
Remove motor fan
cover by pressing down
on clips located on each
side.
Remove the two
screws securing the
brush. Repeat the
process for the other
side.
Pull brush out from
wire clip.
Remove brush from wire
clip by sliding off
groove. If brush is worn
down to a length of
0.25” or less, replace
brush.
To replace or reinstall
brush, repeat process in
reverse.
1
2
3
4
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5.6. Electro Motor Brush Inspection:
NOTE: A motor brush should be replaced if its length is less than 0.25 inches.
Carefully dislodge the
plastic motor cap via the
built-in hooks on both
sides of motor brush.
(TIP: Dislodge
one side
of a cap first followed
by the other.)
With a flathead
screwdriver, flip brush
tab upward. Use pliers
to then pull the brush
out by the tab.
If the brush is worn
down to a length of
0.25” or less, replace
the brush. To replace
or reinstall brush, hold
down internal spring
using the tool supplied
with brush.
While holding spring
down, push the brush
back in. Remove the
brush tool once the
brush is in.
Push the motor brush
in until it’s flush.
1
2
3
4
5
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6.
Troubleshooting
Problem
Possible Cause
Corrective Action
Insufficient
Vacuum
Hose Blocked
Unplug hose
Filter clogged or
improperly seated
Follow filter inspection procedure
Vacuum leak
Check that motor deck is properly seals and secured. Also,
check all hoses
Air Leaks
Worn or poorly seated
seals. Retainers improperly
installed
Block the inlet with a flat and rigid material to place the unit
under vacuum pressure then remove retainers and turn the unit
off. Inspect the seals for completeness, then reset and secure
components again under vacuum pressure
Unable to
control pump
manually
Incorrect setting
Remove the motor deck, then check that the internal sump
pump switch is set to the manual “HAND” position, i.e. the
switch is pushed up.
Unusual or
high pitched
Noises
Motor Bearings, turbine
bearing
Follow relevant motor / turbine inspection procedure. Check
motor bearings for noise by hand.
Worn or poorly seated
seals. Retainers improperly
installed
Block the inlet with a flat rigid material to place the unit under
vacuum pressure then remove retainers and turn the unit off.
Inspect the seals for damage. Then reseat and secure
Components under vacuum pressure.
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7.
Technical Information:
BDC-SLURRY PRO (110 Single Phase)
CFM
200
Electrical consumption
1x 120 Volt
Frequency
60 Hz
Amperage consumption
19 Ampere
Length
50.68 in
Width
31.5 in
Height
59.11 in
Weight machine
346 Lbs
Work width
32 in.
Length of Power Cord
25 ft.
Storage Capacity
32 Gal.
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8.
Slurry Vacuum Parts Breakout:
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9.
Slurry Vacuum Parts List:
ITEM
NO.
PART NO.
DESCRIPTION
QTY.
1
93280500
DOUBLE STACK FRAME, SLURRY VAC, NON-EX
1
2
93280200
SLURRY COLLECTION ASM
1
3
93280100
FILTER MODULE, SLURRY VAC
1
4
90223WNSA001
SLURRY VAC MOTOR DECK ASSEMBLY, 110V
1
5
5018SLRY
FLOOR TOOL, 32IN, 2IN CONNECTION, SLURRY VAC
1
6
E989NNJ04
ENLCOSURE, W/SWITCH, PVC, SLURRY VAC
1
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10.
Filter Module Parks Breakout:
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12.
Filter Module Parts List:
ITEM
NO.
PART NO.
DESCRIPTION
QTY.
1
34823009
HOUSING SPACER, SMALL, RED, CLAMP PLATE HOLES
1
2
9675PLATE
NA CARTRIDGE FILTER PLATE
1
3
10007147
FILTER CARTRIDGE, 10.25 X 7.875
2
4
31406SA
LATCH PULL CLAMP LEVER ASM
2
5
10003683BRACKET
FILTER HOLD DOWN BRACKET, ALCOA
4
6
34812D
SPACER, 1/4" SCH40, 1/2" LONG
4
7
32861S
WASHER SPLIT LOCK M8 SS
4
8
200179
HEX BOLT 1/4-20 X 3/4" SS
1
9
328660
HEX BOLT M8 X 30 SS
4
10
34816S
HEX BOLT M6 X 30 SS
4
11
34876S
M6 LOCK NUT
4
12
200180
WASHER FLAT .25 (.688OD) SS
2
13
250025S
NUT LOCK .25-20, SS
1
14
565058A
REAR STACK ASM, DOUBLE STACK, RED, SLURRY VAC
1
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