Blastrac BDC-955 Dust Collector Operating Manual PDF

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Summary of Content for Blastrac BDC-955 Dust Collector Operating Manual PDF

OPERATING MANUAL BDC-955 VERSION 2.1

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EC DECLARATION OF CONFORMITY

in accordance with Appendix II sub A of Directive 2006/42/EC BLASTRAC B.V. Utrechthaven 12 NL - 3433 PN NIEUWEGEIN Tel: 0031 (0)30 601 88 66 Fax: 0031 (0)30 601 83 33 Info@Blastrac.nl The Netherlands We declare under our sole responsibility that the machine as described below conforms with the Health and Safety requirements of the European Directive for machine Safety. In case of changes to the machine without our written authorization this declaration loses its validity. Model: Blastrac BDC-955-0000 Serial number: xxxxxxx

1. satisfies the conditions set out in the Machine Directive (Directive 2006/42/EC); Low voltage directive (2006/95/EC, as last amended; EMC directive 2004/108/EC, as last amended)

2. satisfies the following harmonized standards:

NEN-EN 292-1, NEN-EN 60335-1, NEN-EN 60335-2-69, NEN-EN 55014, NEN-EN 55014-2 and NEN-EN 61000-3-2

Nieuwegein 28-05-2009

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Table of contents

EC Declaration of Conformity 02

1. Introduction 04

2. Machine description 04 Application & functioning

3. Safety 08

Safety precautions - general Safety precautions - with regard to transport Safety regulations

4. Before operation 10

Checkpoints of electrical safety

5. Operation 10 Switch on the machine Work with the machine Emptying the dust bin Interrupting work Exchanging the dust bag

6. Maintenance 12 Filter replacement Pulse system Water separator Compressor

7. Technical data 20

Contact 21

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1. Introduction It is important that all persons who are working or maintaining this machine read the manual carefully and understand it fully. Keep this manual near to the machine, so it can always be consulted. Only authorized and trained personnel may operate this machine.

2. Machine description The Blastrac dust collector BDC-955 can only be used for dry cleaning. It should only be used for removing not-inflammable dust or substances. The BDC-955 must not be used for carcinogenic or asbestos substances. The machine is designed for usage in conditions according to classification M (see below).

Classification acc. standard EN 60335-2-69 Annexe AA

Type Class Designation

BDC-955 M (Medium risk) for separating dust with an exposure limit value of over 0,1 mg/m3, depending on the volume occupied.

Dust emissions into the environment

Class Value of performance

L Retains at least 99,1 % of particles measuring 3 m

M Retains at least 99,9 % of particles measuring 3 m

H Class H13 HEPA filter in accordance with EN1822

The BDC-955 is available in 2 versions: 400-440 Volt 50 and 60Hz version. Application The BDC-955 is especially designed to be used in combination with Blastrac Blasting machines and scarifiers.

Contact Blastrac B.V. for the correct execution and combinations.

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ITEM DESCRIPTION

1 WHEELS

2 FILTER CHAMBER

3 PULSE CHAMBER

4 CONTROL PANEL

5 WATER SEPARATOR

6 AIR PISTOL

7 PULSE SYSTEM

8 PULSE CONTROL

9 FAN UNIT

10 HOIST BEAM

11 COMPRESSOR

12 SILENCER

13 END PART

14 DISCHARGE & BAG UNIT

15 COVERS

16 HOSE ADAPTER

17 BIG BAG

FOR DETAIL OF CONTROL PANEL, SEE FIGURE 2.2

FIGURE 2.1 MACHINE OVERVIEW

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FILTER CHAMBER Contains 9 filter cartridges for the separation of dust from the airflow. PULSE CHAMBER Separates the filter chamber from the clean air side and seals the filtercartridges. CONTROL PANEL Controls the functioning of the dustcollector and powersupply to the applications (see figure 2.2). WATER SEPARATOR Separation of water from the pulse system. The separator drains automatically. Optional a small bottle (approx. 20 30 c.c.) can be placed in the holder below the separator, in order to prevent the fluid contaminating the floor. AIR PISTOL Accessory for cleaning the dustcollector. PULSE SYSTEM For pulse cleaning of. Increases life-time of the filtercartridges by pulse cleaning. PULSE CONTROL Controls the pulse valves. FAN UNIT Creates an airflow for a correct functioning of the combined application. The air flow through the complete system during the application of the blast cleaning machine and the dust collector has the following functions:

Cooling of the blast wheels

Cooling of the abrasive

Transport of the abrasive

Transport of dust through the system

Separation of dust from the re-useable abrasive

Transport of dust to the dust collector

HOIST BEAM Single hoisting point for transport of the dustcollector. COMPRESSOR Feeds the pulse system with compressed air. SILENCER Sound damping air outlet with integrated air-flow control valve. END PART Cable support.

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DISCHARGE & BAG UNIT For dust discharge and handling of the dustbags. The discharge tray has an integrated valve which enables continuous working with the combined application. HOSE ADAPTER Accessory which enables connection of a 5 (130 mm.) suction hose, instead of the standard 6 (150 mm.) hose. BIG BAG Captures and simplifies a hygienic transport of the processed dust. 1 dustbag is delivered with the dustcollector. The dustbags are sold separately in sets of 50 pieces (part E06311).

Main switch The main switch is located on the main box. It has to be switched on before operating the dust collector and the blast cleaning machine. Button Compressor/Fan ON/OFF Pressing the button "ON" switches the compressor / fan on, pressing the button "OFF" switches the compressor and the fan off. Button Screwconveyor ON/OFF (optional) Pressing the button "ON" switches the (optional) screw conveyor on, pressing the button "OFF" switches the compressor and the fan off. Control lamp Thermical failure This lamp shines when the machine is overloaded. Control lamp Phase incorrect This lamp shines when there is a failure with the phases.

FIGURE 2.2 - DETAIL OF CONTROL PANEL

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Emergency shutdown switch Red mushroom-shaped press switch onto a yellow background. Pressing this switch immediately stops the power supply to all units of the machine, shut down switch requires re-setting after it has been used. Connectors Enables the connection of an application, e.g. a Blastrac blasting or scarifying machine. Hour counter Shows the working time of the Dustcollector in hours. Registration of the working hours enables to follow a correct maintenance schedule.

3. Safety Before operating the machine, the personnel must be familiar with the safety instructions given in this manual. Keep this manual near to the machine, so that it may always be consulted. Safety precautions general

It should only be used for removing not-inflammable dust or substances. The unit should not be used near flammable gasses or substances. The BDC-955 must not be applied for carcinogenic or asbestos substances. Packing material, like plastic bags, should not be in reach of childrens with regard of asphyxiation

danger. The voltage on the identification plate must comply with the power supply. Do not use the unit when it is damaged. Do not use damaged extension cables. Do not pull the power supply cable over sharp edges, fold the cable or clamp it. Never use this machine for sucking water or liquids. Acids, acetone or solvents can damage the machine. During a standstill of the machine, pull out the plug. Dont pull out the power supply cable out by the wire, but by the connector. Use only original Blastrac parts. The dust collector must be yearly overhauled by a skilled technician.

Safety precautions with regard to transport

Remove the dustbag from the dust collector and close the discharge valve before it is transported. Close the silencer valve outlet of the dust collector. The dust collector may only be lifted by using the (single point) hoisting beam. It may by tightened by fastening straps to the indicated points on the housing frame (see chapter 2). The weight and dimensions of the dust collector are shown in Chapter 7 "Technical data.

When transporting the dust collector do so in such a manner that damage due to the effects of the use

of force or incorrect loading and unloading is avoided. Before the dust collector is removed from the hazardous zone, take precautions to prevent dust from

escaping. Always close the inlet of the dust collector with the appropriate plug

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Safety precautions with regard to maintenance

To allow the user to carry out maintenance operations, the dust collector must be disassembled, cleaned and inspected as far as reasonably possible, without causing hazards for the maintenance staff or other people.

The suitable precautions include decontamination before disassembling the dust collector, adequate filtered ventilation of the exhaust air from the room in which it is disassembled, cleaning of the maintenance area and suitable personal protection.

The external parts of the dust collector must be decontaminated by cleaning and vacuuming methods, de-dusted before being taken out from the hazardous zone. All parts of the dust collector must be considered as contaminated when they are removed from the hazardous zone and appropriate actions must be taken to prevent dust from dispersing.

When maintenance or repair procedures are carried out, all the contaminated elements that cannot be properly cleaned, must be destroyed.

These elements must be disposed of in sealed bags according to the applicable regulations and in accordance with the local laws governing the disposal of such material.

This procedure must also be followed when the filters have to be disposed. Compartments that are not dust-tight must be opened with suitable tools and thoroughly cleaned.

Safety regulations

The following sticker is placed on the machine.

Meanings of these symbols are:

Ear protection is obliged Safety glasses with lateral protection are obliged CE-mark on this machine Safety shoes obliged Consult the manual before operating the machine

Personnel must tie back long hair and not wear loose clothing or jewellery including rings. Wear gloves and dust mask during operating the machine.

Persons who are not operating the machine must not be permitted to stay in the surrounding area of the machine.

Dont change anything on the machine. Use always cables which are approved and safety earthed (extend) cables. The machine is always equipped with an earthed connection, do not change this and use always earthed cables with an earthed plug.

Connect the main power supply cable to an installation with an earth leakage circuit breaker. Inspect and test the electrical components regularly. The electrical components have to satisfy to the

requirements which apply to these components. Always call a skilled electrician or your distributor when you have questions about the safety of the

electrical components. 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.

Pull out the main plug during inspections and repair operations on the machine. Never operate the machine when the surface is wet. Never use the machine in the rain.

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4. Before operation Before using the machine it is essential to inspect the machine. It is not permitted to use the machine if the machine safety is not according the checkpoints below.

Checkpoints of electrical safety

Use only extension cables for extending the main cable that are sized and marked in accordance with the overall power consumption of the machine.

Electrical cables must be rolled entirely off of the reels. Any damage to electric cables is not permitted Use an electrical power supply connection with earth connection. The main switch of the machine should be put to Off before connecting to the power supply.

5. Operation

Switch on the machine

Connect the dust hose to the machine. Attach a dustbag in the bag lifting system and secure the opening of the bag to the discharge outlet

with the belt. Open the valve of the discharge (handle position up) Make sure the switches of the dust collector are in Off position. Connect the dust collector to the power supply. Switch on first the compressor motor. Secondly switch on the fan motor. Start working with the machine.

Work with the machine

Regular check the contents of the dust-bag. When full, proceed with Exchanging the dust-bag. Read-out the pressure indicators on the pulse chamber regular and check for a functional pulse-

cleaning on the dust-collector.

Interrupting work

When temporarily interrupting the work (1/2 hour 1 hour), turn-off the fan-unit only. Pulse-cleaning of the filter-system will continue and will increase the life-time of the filter-cartridges.

During a longer stand-still of the dust-collector, first switch-off the fan-unit. Let the pulse-cleaning cycle run for +/- 5 minutes. Switch-off the compressor unit and Main-switch.

Disconnect the power-supply cable. Prevent un-authorized persons from getting access to the dust-collector or take measurements to

prevent un-authorized working with the equipment.

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Exchanging the dustbag The dust-bag can be replaced during working with the dust-collector by closing the valve on the discharge- outlet. The capacity of the discharge-bin enables continuation of the working process.

Check regularly the level of the dust-bag. The periods of checking depends on the surface to be cleaned.

When the dust-bag is full, close the valve of the discharge-outlet (valve handle horizontal).

FIGURE 5.1 Loosen the belt of the bag-inlet. Seal the bag-inlet by means of the chords on the bag. Slowly drop the bag on the ground by tilting the bag lifting handle up.

FIGURE 5.2

Remove the straps out of the lifting unit and replace the full bag by a new. Lift-up and seal the bag with the belt. Open the valve of the discharge-outlet (valve handle vertical). Dispose the full bag. Observe the waste disposal regulations; in uncertain situation ask your next

policy level.

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6. Maintenance

Pay attention to Chapter 3 "Safety" during maintenance and repair works. Failures due to inadequate or incorrect maintenance may generate very high repair costs and long standstill periods of the dust collector. Regular maintenance therefore is imperative. Operational safety and service life of the dust collector depend, among other things, on proper maintenance. The following table shows recommendations about time, inspection and maintenance for the normal use of the dust collector.

Operating hours/ time period

Inspection points, maintenance instructions

12 h after repairing Check all accessible screw connections for tight seat.

Daily and prior to starting work

Check all safety devices working adequate. Check the function of the residual current operated device. Check the hose connections for tightness and fixed seat. Check the hose to the filter for damages. Make sure that the dust bin of the filter is emptied Check the electric connections for sediments of dirt or foreign bodies. Check the electric motors for dirt and other contaminants.

Annually Full overhaul and cleaning of the complete dust collector.

After 50 working hours Change compressor oil.

After 300 working hours, using mineral oil

Change compressor oil.

After 900 working hours, using synthetic oil

Change compressor oil.

The time indications are based on uninterrupted operation. When the indicated number of working hours is not achieved during the corresponding period, the period can be extended. However a full overhaul must be carried out at least once a year. Due to different working conditions it cant be foreseen how frequently inspections for wear checks, inspection, maintenance and repair works ought to be carried out. Prepare a suitable inspection schedule considering your own working conditions and experience.

Our specialists will be happy to assist you with more advice.

Prior to any repair works on the dust collector and its drives, secure the dust collector against unintentional switching-on. Put the dust collector to its safety off position. Also make sure there is no air pressure on the pulse system.

Follow additional operating and maintenance of OEM if included during your service and maintenance work.

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Further is advised: Store the cleaned and dry machine in a dry and humid free room. Protect the electrical motors from moisture, heat, dust and shocks. All repair work must to be done by qualified Blastrac personnel, this to guarantee a safe and reliable machine. Any guarantee on the machine is expired when:

Non original Blastrac parts have been used Repair work is not done by qualified Blastrac personnel Changes, add ons or conversions are undertaken without written permission of Blastrac BV

Filter replacement

1 Switch off the dust collector and pull out the power supply. 2 Loosen the top bolts of the hoisting beam (do not remove them). 3 Loosen the hose on pulse-chamber. 4 Loosen the bolts of the pulse-chamber at the hinge position. 5 Loosen the nuts of the eye-bolts (do not remove them) and swap the eye-bolts up. 6 Rotate the center-handles left & right up, to ease tilting the pulse-chamber up. 7 Remove the safety (quick release) pins.

8 Lift the pulse chamber up. 9 Lock the pulse chamber in upward position by inserting the quick-release pins at the original position. 10 Replace the filter-cartridges.

2 3

4

6

2

7

FIGURE 6.1

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11 Follow above given procedures in reverse to restore the pulse-chamber position. Carefully and evenly

tension (in cross-direction) the bolts and nuts in order to obtain an adequate sealing. Torque the tension devices with 26 up to 30 Nm.

12 When hose and hoisting beam are mounted back in position, start the fan-unit. Due to the vacuum in the filter-unit the pulse-camber may slightly be pressed further in its sealing.

13 Check and re-tension the pulse-chamber when necessary. 14 Continue work with the dust-collector.

Pulse system

The Dust collector is provided with a air pulse cleaning system which increases the life of the filter cartridges. The system works by use of pressurized air, built up by a belt driven compressor The air is leaded through a waterseparator to the pulse system.

Compressor Water separator

FIGURE 6.3

FIGURE 6.4

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9 9

8

FIGURE 6.2

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Pressure gauge

FIGURE 6.6

The conditioned air then passes a control valve (see fig. 6.5), which regulates the systems pressure , and then builds up pressure in the pulse tank.

Normally the pressure in the system lies between 6 and 7 bar. The safety valve mounted on the pulse tank is activated at approximately 10 bar. This provision is to ensure that when there is a defect in the Control valve, the pressure in the pulse tank remains within safe limits. The pressure in the pulse system is indicated on the pressure gauge. It is mounted in the Filter house next to the vacuum gauge. If the pressure of 7 bar is not reached, it is possible that either the filter of the water separator or the air filter of the compressor is dirty. For maintenance instructions on the waterseparator and the compressor see the applicable paragraphs.

Pulse tank Safety valve

Control valve

FIGURE 6.5

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Level indicator

marking

Outlet ring FIGURE 6.9

FIGURE 6.8

If inspection on the waterseparator or compressor shows no dirty filter, it is possible that either there is a leakage in the air tubing, or the control valve is defect. In that case replace the defective parts or have it checked by Blastrac. When there is pressure but the pulse system does not function, there might be a problem in the electrical system which controls the pulsing system. Check the wiring and the PLC-settings. Advised is to take contact with Blastrac Support in order to prevent operational problems. Water separator Periodically check the level indicator of the waterseparator. If there is condensate level approximately 10 mm below the level indicator marking (see figure 6.8 ) then either press in or turn the outlet ring as shown on figure 6.9 .

FIGURE 6.7

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In case of less air flow as mentioned in the paragraph above, replace the filter of the waterseparator as following: Push unlocking slide down and turn filter bowl in anti-clockwise direction. Then pull filter bowl away from the separator.

Turn the filter screw loose and replace the dirty filter by a new one as shown on figure 6.11 . Hold the new filter element only at the lower end .

Fasten the filter screw and place the filter bowl back . Make sure the locking pin points towards the large recess (see figure 7.10.5 ). When fastening the filter bowl, make sure you hear a clear snap.

FIGURE 6.11

FIGURE 6.10

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Compressor The oil level and air filter of the compressor should periodically be inspected acc. to the inspection table given values. Replacement or cleaning of the air filter is depending on the environment in which the Dust collector is operating.

FIGURE 6.12

FIGURE 6.13

Air

filter

FIGURE 6.14

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The height of the oil level oil level must lay on approximately half of the oil level indicator , about 0,25 liter. Use only oil especially mend for compressors, according specification C.T. 68 ( ISO 68 viscosity ) . Prior to draining-off , the compressor unit should have operating temperature.

FIGURE 6.15

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7. Technical data

BDC-955

Power consumption 5.5 kW

Electrical connection / fuel 400-440V / 50-60Hz

Air stream

(hose end) 1324 m3/hr

Dust hose connection 130 - 150 mm

Total filter surface 36m2

Length 980 mm

Width 820 mm

Height 1500 mm

Weight, with cable ( / cable loose) 552 kg ( / 538 kg)

Noise level (at 1 mtr. distance) Up to 95 dB(A)

Design and specifications are subject to change without notice by Blastrac B.V.

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Headquarter Blastrac The Netherlands

Utrechthaven 12 NL 3433 PN Nieuwegein Tel 0031 30 601 88 66 Fax 0031 30 601 83 33

Info@blastrac.nl

Blastrac Poland Golina, Dworcowa 47a PL 63-200 Jarocin

Tel 0048 627 40 41 50 Fax 0048 627 40 41 51

Info@blastrac.pl

Blastrac Italy S.S. 10 Padana Inferiore, 41

IT 29012 Caorso (PC) Tel 0039 0523 81 42 41 Fax 0039 0523 81 42 45

Info@blastra.it

Blastrac United Kingdom Unit 2, Outgang Lane, Dinnington

Sheffield, South Yorkshire GB S25 3QY, England

Tel 0044 1909 56 91 18 Fax 0044 1909 56 75 70

Info@blastrac.co.uk

Blastrac Germany Richard Byrd Strae 15

D 50829 Kln (Ossendorf) Tel 0049 221 70 90 32 0

Fax 0049 221 70 90 32 22 Info@blastrac.de

Blastrac Spain Calle Copernico, 16

Nave 2 E 28820 Coslada

Tel 0034 91 660 10 65 Fax 0034 91 672 72 11

Info@blastrac.com.es

Blastrac France (ZI)

29, Avenue des Temps Modernes F 86360 Chasseneuil du Poitou

Tel 0033 549 00 49 20 Fax 0033 549 00 49 21

Info@blastrac.fr

Blastrac Ukraine Nezalezhnosti 14, of. 21

UA 07400 Brov

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