BioJet 2100C. 1. Introduction 2

Transcription

1 Contents 1. Introduction 2 2 Warnings and important notes Safety rules concerning the delivery device MS Safety rules concerning the vacuum filter unit model P Safety rules concerning the cabinet model 2100C 4 3. Requirements for system operation Placement requirements Air requirements Electricity requirements Blasting media requirements 5 4. Instructions Set-up instructions pressure delivery unit MS Set-up instructions vacuum filter unit P Set-up instructions cabinet model 2100C Operating instructions Filling up the pressure delivery unit MS-60 up during a blasting cycle Rinsing after powder blasting Cleaning cycle description Technical system description Pressure delivery unit MS-60-BM Vacuum filter unit P Automated cabinet model 2100C Maintenance Maintenance for the pressure delivery unit MS Maintenance for the vacuum filter unit P Maintenance for the cabinet model 2100C Troubleshooting Troubleshooting for the pressure delivery unit MS Troubleshooting for the vacuum filter unit P Troubleshooting for the cabinet model 2100C 30 BicarBlast B.V. Sigarenmaker DJ Eersel - The Netherlands BioJet 2100C Rev. 2 Page 1

2 1. Introduction Cleaning anilox rolls can be done in several ways. A very special method is blasting your anilox rolls with BicarBlast TM Maintenance powder. This method is best explained as breaking off coating pollution through the impact of the powder on the anilox roll surface. The BicarBlast TM maintenance powder is baking soda (sodium bicarbonate) which is hard enough to clean your anilox roll, but at the same time is too soft to damage your ceramic or chrome anilox roll surface at the recommended blast pressure. The cleaning installation of the BioJet cabinet model 2100C can be divided into three main components; namely the pressure delivery unit MS-60, the cabinet model 2100C and the dust collection system P2. The cleaning installation is designed according to the CE regulations. The pressure delivery unit MS-60 transports the blasting powder from the pressure vessel to the spray head. In the pressure delivery unit, model MS-60, the blast powder is dosed to the compressed air flow which and both components are mixed and released at the spray nozzle. The persurre delivery unit is TüV certified. The closed cabinet model 2100C with a automated roll mechanism and traverse for the nozzle allows you to clean your rolls without any supervision at the installation during the blasting procedure. The pressure delivery unit MS-60 and dust collection unit P2 are switched on and off by the automated cabinet. Furthermore the cabinet model 2100C is equipped with safety securities like a automatic door lock during operation and automated close-down provision in case of technical failures. Dry powder blasting causes a lot of dust because the relative soft baking powder pulverises on the anilox roll surface. The dust collection unit P2 and the cyclone model 4 keep the environment of the BioJet cabinet model 2100C dust free. Because of the vacuum pressure, most of the dust (95% - 99%) is collected in the cyclone model 4. The remaining dust is separated in the filter which is cleaned automatically by reverse pulse purge. Rev. 2 Page 2

3 2 Warnings and important notes BioJet 2100C 1. Not following the described operating and maintenance instructions and the warning signs on the BioJet installation can result in serious injury. 2. NEVER operate the system when a part of the installation has been removed or disconnected. 3. Always disconnect tubes and power connectors to and from the system if any maintenance is performed. 4. All personnel in the area must be furnished with the appropriate certified safety equipment when safety limits are exceeded, particularly for eye protection and protection of hearing and breathing. 5. NEVER deviate from the set-up instructions or change any component. 2.1 Safety rules concerning the delivery device MS Always DE-PRESSURISE the unit before maintenance or loading. The unit should NEVER be pressurised if the tubes are not connected properly. DO NOT remove, repair or replace any item connected to the pressure vessel when it is pressurised. 2. The pressure delivery device MS-60 is only to be used with compressed air. The maximum inlet pressure of the delivery unit is 10 bar. Never exceed the safe working pressure by connecting the system to a compressed air source exceeding 10 bar. The maximum admissible temperature is 50 C and the minimum admissible temperature is 0 C. 3. Never aim the blast nozzle into open space and be sure it is mounted properly and tight in its clamp. Not following the instructions can result in serious injury. 4. The pressure vessel is TÜV certified and the system pressure of the delivery unit is limited to 4.0 bar with a spring valve. Never increase the system pressure (optimal performance is achieved at 2.8 bar). 5. Never weld, grind or sand the pressure vessel because any damage or change to the vessel can make it UNSAFE. 2.2 Safety rules concerning the vacuum filter unit model P 2 1. DO NOT disconnect any tubes or cables while the vacuum filter unit is operating. 2. Check if the collection bag under the elevator box is tightened close to the drain pipe. If the air flow is too big the vacuum blower will be damaged permanently. 3. DO NOT empty the cyclone collection vessel or collection bag of the filter without eye- and breathing protection. The toxicity of the removed coatings must be considered to determine the proper selection of safety equipment. 4. Cleaning of the cartridge filters is only done by the automated reverse pulse purge. The air pressure for the cartridge filter cleaning must be adjusted between 4 and 5 bar. Exceeding 7 bar will result in permanent damage of the cartridge filter. 5. NEVER open the filter unit while the system is working. 6. NEVER connect the vacuum filter unit P2 directly to the cabinet. Always use the cyclone model 4 to protect the vacuum filter unit. 7. NEVER use a collection bag in the barrel of the cyclone. Rev. 2 Page 3

4 2.3 Safety rules concerning the cabinet model 2100C 1. When putting an anilox roll into the cabinet, always set side holders at the outer limits. When a roll is taken out of the cabinet these side holders also need to be set at their outer limits. 2. NEVER disconnect or change any electrical component to let the system operate if not complying with the original operation or set-up. 3. Avoid moistured vapour in the cabinet in order to prevent sticking of media in the cabinet or in the dust collection system. The increased humidity will cause blockage of the air flow channel and filter cartridge while the media becomes sticky. 4. The maximum admissible total roll length to put in the cabinet for model 2100C is 2100 mm. The length of the roll body should be between 500 and 2100 mm. Exceeding these limits can result in damage of the equipment or serious injury. 5. NEVER modify the cabinet in order to open the door during blasting. 6. NEVER push the button that indicates that the door is closed by hand or any other object than the door itself. When this button is pushed while the door is opened the programme can be started and the powder will be blown out of the cabinet. 7. Always close and open the cabinet door by using the door handles only. Never close or open the door by pushing or pulling it at any of it s edges. This can cause serious injury s at hands and arms. 8. Never put rolls inside the cabinet heavier than 300 kg. These rolls will permanently damage the cabinet, causing failure and dangerous situations. 9. Always put the rolls gently into the cabinet. NEVER let them FALL into the cabinet. This will cause permanent damage to the cabinet. 10. Always connect the cabinet to an electrical point with a protective ground pin and always use a cable with a wire for this protective ground pin. 11. DO NOT connect any other device to any of the cabinet connectors than the devices that are mend to be connected to these connectors. Rev. 2 Page 4

5 3. Requirements for system operation 3.1 Placement requirements 1. The floor where the installation is set-up must be solid and horizontally levelled. 2. All components need at least 2 meters of free space on the front side to load and empty them. For example the (un)loading of rolls, filling up the delivery unit with powder, cleaning, etc. 3. The delivery unit needs 1 meter of space on both the left and right side to make all hose connections and valves accessible. 4. The cabinet also needs 1 meter space on both sides in order to adjust the distance and aim the nozzle towards the roll surface. 5. The cyclone dust separator has to be placed in such a way that it can be moved to empty it. 6. The vacuum filter unit P2 needs to be accessible on the rear side and needs 1 meter of space on the left and right side. 3.2 Air requirements 1. Compressed air with a capacity of 1.2 m3/min (8.8 kw) for blasting at 2.8 bar pressure with a 1/4 blast nozzle. 2. A capacity of 2 m 3 /hour is enough to operate the reverse pulse cleaning of the vacuum filter unit. 3. The minimum inlet air pressure for the delivery unit MS-60 is 3 bar and the maximum inlet air pressure is 10 bar. An inlet pressure of 4.0 bar is recommended to assure optimal performance. 4. The minimum temperature of the compressed air may not be below freezing temperature. This is necessary in order to separate the moisture from the air. The maximum compressed air temperature is 50 C. 3.3 Electricity requirements 1 The cabinet model 2100C requires 380 VAC, three phase current, plus zero plus protective ground. The current requirement is 10 Ampere. The cabinet is equipped with two 8 Ampere and one 10 Ampere fuses. 2 The electrical power needed for the industrial blower and the reverse pulse cleaning is supplied by the cabinet. The red connector is used for the industrial blower and the blue connector is used for the timers of the reverse pulse cleaning. Never connect any other device to these connectors. 3 The power consumption of the industrial blower is 1.2 kw. 3.4 Blasting media requirements 1. To ensure the quality of this cleaning method for ceramic and chrome anilox rolls, only BicarBlast TM Maintenance blasting powder is used for this application. Any other powder can cause damage to your roll surface or blasting equipment. The powder cannot be used again after blasting. 2. The powder can only be used when it is kept on a dry place above 0 C. Rev. 2 Page 5

6 4. Instructions 4.1 Set-up instructions pressure delivery unit MS-60 (See the overview drawing on page 8 for all connections) 1. Close the inlet air valve (3), choke valve (8) and tank vent (11). 2. Connect the compressed air supply (1) to the T-connector on the vacuum filter unit. Connect the air tube between the T-connector and the pressure delivery unit. 3. Connect the blast hose (14) from the cabinet to the delivery unit. Secure the connector at the pressure delivery unit. 4. Connect the blue and grey hose for the air control to the right side of the frame of the pressure delivery unit and to the bottom of the control panel. 5. Open the media control valve (7) and the choke valve (8) completely Open the air inlet valve and the pop-up valve will close the pressure vessel. 7. Adjust the tankpressure at 2.8 bar. Increase the tank pressure (5) by closing the pressure regulator (4). Decreasing the tank pressure is done by turning the pressure regulator (4) open and depressurize the tank by opening the tank vent for a short moment. 4.2 Set-up instructions for the vacuum filter unit P2 (See the overview drawing on page 8 for all connections) 1. Connect a 4 hose from the right bottom side of the cabinet to the horizontal tube of the cyclone. Tighten the hose with clamps on the cabinet and the cyclone side. 2. Connect a 4 hose from the top of the cyclone to the entrance of the vacuum filter unit. The entrance of the vacuum filter unit is on the rear side. Tighten the hose with clamps on the cyclone and vacuum filter unit side. 3. Put the power connectors of the vacuum filter unit in the connectors mounted on the left side of the control panel of the cabinet. 4. Adjust the inlet air pressure of the vacuum filter unit P2 between 3 and 5 bar. 5. The timers for the pulse jet purge should be adjusted at an interval time of 0.5 min. and a pulse duration of 100 ms. Rev. 2 Page 6

7 4.3 Set-up instructions cabinet model 2100C (See the overview drawing on page 8 and 9 for all connections and operation instructions) 1. Put the plug in a 380 Volt with zero and protective ground electrical point and turn the main power switch on. 2. Open the door of the cabinet using the door handles only. The red warning light on the control panel will start flashing immediately. 3. Release the clamps, that prevent the roll from drifting over the wheels, on the front bar and push both side holders to the outmost left and right. 4. Release the nozzle from its bracket and push it back so that a roll can be placed on the wheels. Fasten the nozzle so it can not slide back. 5. A roll can now be laid gently on the wheels of the shafts. Only rolls with a diameter between 100 and 200 mm, a face length between 250 and 900 mm and a maximum total length of 900 mm can be put into the cabinet. The roll may not be heavier than 250 kg. 6. Now push the left and right side holders over the bar and fix the holders so that they approach the side of the roll body less than 1 centimetre. 7. Release the nozzle and pull it forward to the roll surface until the distance between the nozzle and the roll is approximately 10 centimetres. Then fix the position of the nozzle. 8. Close the door using the door handles only. Then adjust the left and right limit for the blast nozzle on the top box behind the door. This is done by releasing the screw and pushing the arrows until they are being placed above both sides of the roll body. 9. Adjust the roll diameter with the knob on the control panel. Taking a roll diameter a little bit bigger than the actual roll diameter will always assure you total coverage of the roll surface. 10.Adjust the number of passes (one pass is from the right to the left limit and back) that the spray-nozzle should travel during blasting. The maximum number of passes is four. 11.After closing the door, the green light flashes for three seconds and then remains on. If the green light is not on, close the door firmly again. The cleaning cycle cannot be started if the green light is not permanently on. 4.4 Operating instructions (See the overview drawing on page 9 for operation instructions) 1. When all the set-up instructions are executed properly the start button can be pressed. 2. When the blasting starts readout the differential pressure gauge on the front of the pressure delivery unit MS-60. The differential pressure is adjusted by closing or opening the media control valve on the left side of the MS-60. The differential pressure is adjusted at 1 PSI when blasting BicarBlast Maintenance powder. Warning! : If the differential pressure is set higher than 1 PSI the use of blasting powder will be higher. 3. The further cleaning cycle is completely automatic. When the blasting is finished and the green light is lit, the roll can be taken out of the cabinet or the cleaning can be repeated. After the roll is taken out it needs to be rinsed to remove dust particles. See paragraph 4.6 for the instructions on rinsing. Never use any liquids inside the cabinet. Rev. 2 Page 7

8 System connections Rev. 2 Page 8

9 Cabinet connections and operation 4.5 Filling up the pressure delivery unit MS-60 during a blasting cycle 1. Press the stop button on the control panel of the cabinet. 2. Wait until the cabinet has completed its program and the green light is burning. 3. Close the inlet air valve of the pressure delivery unit. 4. Open the tank vent and the vessel will depressurize via the silencer. 5. When the tank pressure is zero the pop-up valve will fall and powder can be put into the pressure vessel. 6. Close the tank vent and open the inlet air valve. 7. Adjust the number of passes on the control panel of the cabinet to the number of passes that you want the cabinet to finish. 8. Press the start button to finish the cleaning of the roll. 4.6 Rinsing after powder blasting After BioJet cleaning with BicarBlast Maintenance the rolls need to be rinsed with a cleaning liquid. It is also possible to use warm water, but our cleaning liquid is preferred. Rev. 2 Page 9

10 Never use any liquids for any reason in the blasting cabinet. Liquids in the cabinet will destroy the vacuum unit and will cause blockades in the air flow channels. BicarBlast recommends a solution with Acidic 50 from Rogier Bosman Chemie. This cleaning product is delivered in a concentrated form and needs to be diluted with warm water (40 o C) until a 5 % concentration is achieved. Clean the anilox roll with this solution and a sponge to solve calcium deposit and blasting powder that is left behind in the cells. After washing with the cleaning solution the roll needs to be rinsed with water to neutralise the ph-value. 4.7 Cleaning cycle description When the start button is pressed the red light is on and the door is locked. The cleaning cycle will be controlled automatically. The nozzle travels fast from the outer right side of the cabinet to the right shiftable limit. When the nozzle arrives at the right shiftable limit the blasting by the pressure delivery unit and suction unit on top of the vacuum filter unit are started. At the same time the roll drive starts and the travelling speed of the nozzle is adjusted to the correct speed for the roll diameter. During blasting the nozzle travels between the left and right shiftable limit until the adjusted number of passes is made. When the emergency stop is pressed during a cleaning cycle all the moving parts and the pressure delivery unit will be stopped. The door is also unlocked during an emergency stop. To resume the cleaning cycle release the emergency stop and make sure that the door is closed. Then the green light will flash for three seconds and will remains lit. Then the cleaning cycle can be continued, where it has stopped, by pressing start. The pressure delivery unit, the vacuum filter unit and traverse system are started again and the door is locked. If the adjustments have not been changed, the cycle will be completed. When the number of passes has been achieved a cleaning cycle has been completed. The powder blasting and roll drive are stopped and the nozzle travels fast back to its reference position on the right side. 15 seconds after the nozzle has arrived at the reference position the vacuum unit is switched off and 10 seconds later the filter cleaning starts with a reverse pulse jet purge. 30 seconds later the second reverse pulse jet purge is given. When the green light is on the cleaning the door can be opened and the roll can be taken out of the cabinet. The cabinet now can be restarted. Rev. 2 Page 10

11 5. Technical system description BioJet 2100C The complete BioJet cabinet installation can be divided into three main components namely the pressure delivery system, the vacuum filter unit and the cabinet model 2100C. Each component of the installation will be described in the following paragraphs. 5.1 Pressure delivery unit MS-60. The pressure delivery unit MS-60 has been designed to be interchangeable with the complete program of BioJet products of BicarBlast. The delivery unit is applicable to blast BicarBlast Maintenance formula to remove any coating from ceramic or chrome anilox rolls. The complete pressure delivery unit is manufactured by Gritco Equipment BV in Ridderkerk, Holland. The pressure delivery unit is TüV certified. The Manufacturer s Certificate can be found in the appendix. The principle of the operation is explained below and the components are displayed on photo s on the next pages. 1. Air enters the MS-60 through the compressed-air filter. This filter separates moisture and dust particles from the compressed air in order to improve the compressed air quality. 2. The air inlet valve is opened to let the compressed air into the system. The air inlet valve is opened manually when starting-up and closed when the system is shut down. 3. The air pressure is reduced by the pressure regulator, which is adjusted manually and can be locked. 4. After the air goes through the pressure regulator a part of it enters the pressure vessel. The pressure in the vessel is indicated on the tank pressure gauge. The pressure vessel has a tank vent on the right top side. This vent is opened when the tank pressure needs to be set lower when there is no air flow. In all other cases the tank vent is used to depressurize the tank. The vent is equipped with a silencer. At the same place the pressure safety spring valve is mounted. 5. The other part of the air goes to the pneumatic controlled blast valve. This valve is controlled by an air signal provided by the cabinet. 6. The media control valve is directly after the blast valve. Closing this valve increases the media flow. Opening this valve decreases the media flow. 7. After this the choke valve is mounted which can shut of the blast air. 8. The powder release valve is opened by the same air signal as the pneumatic blast valve. The powder release valve is opened when a piston is pushed away by the air pressure of the control signal. 9. When the piston is pushed away the powder is pressed through the opening into the blast air stream underneath the vessel. 10. Now the powder is transported with the blast flow towards the spray nozzle to clean the roll surface. Rev. 2 Page 11

12 Pressure delivery MS-60 Photo 1 1. Sieve and cover 2. Readout panel 3. Tank vent 4. Hand hole 5. Silencer 6. Air inlet 9. Safety valve 10. Pressure regulator 11. Air inlet valve 12. Compressed air filter 7. Release valve 8. Blast hose connection 13. Air control connections 14. Check valve Photo 2 1. Pressure regulator 2. Air inlet valve 3. Tank inlet 4. Compressed air filter 6. Piping mount 7. Pneumatic blast valve 8. Media control valve 9. Choke valve 5. Air control Rev. 2 Page 12

13 Photo 3 1. Tank pressure 2. Differential pressure 3. Blast pressure Schematic display of pressure delivery MS Inlet air connector 8. Choke valve 2. Compressed-air filter 9. Blast pressure gauge 3. Inlet air valve 10. Pressure tank with media 4. Pressure regulator 11. Tank vent 5. Tank pressure gauge 12. Silencer 6. Pneumatic blast valve 13. Safety spring valve 7. Media control valve 14. Blast hose connection Rev. 2 Page 13

14 Drawing , pneumatic blast valve Air control valve PL 18, Item no Position Number Description Item no. 1 1 PL 18-13, spring Half nut M PL 18-05, U diaphragm plate PL 18-05a, O-ring PL 18-04, shaft Socket cap screw M6 x 25 mm Elbow ¼ x 6 mm PU hose 6 x 4 mm PL 18-09, cap small Socket cap screw M6 x 25 mm PL 18-10, gasket PL 18-01, body PL 18-16, diaphragm PL 18-02, cap big Rev. 2 Page 14

15 Drawing , pop-up valve Pop-up valve composition Position Number Description Item no. 1 1 Tack weld 1¼ ¼ thread pipe Pop-up gasket Pop-up valve head Gasket Upper valve guide Lower valve guide 1¼ Threaded elbow 1¼ Rev. 2 Page 15

16 Drawing , hand hole Hand hole composition Position Number Description Item no. 1 1 Nut M Flat washer Clamp Cover Hand hole gasket rubber U Rev. 2 Page 16

17 Drawing , compressed-air filter Compressed-air filter 1¼, Item no Position Number Description Item no. 1 1 Body Centrifugal plate Protection sleeve O-ring Top holder Gasket Cartridge filter O-ring Bottom holder Rubber gasket Metal bowl with sight glass Drain cock - Rev. 2 Page 17

18 Drawing , pressure regulator 1¼ Pressure regulator 1¼, Item no Position Number Description Item no. 1 1 Cap, complete Disc spring Spring Piston Piston gasket Safety clip O-ring Safety spring Body, 1¼ screw thread Tube valve and seat, complete Spring O-ring 13 1 Cap - Rev. 2 Page 18

19 Drawing , powder release valve Powder release valve, Item no Position Number Description Item no. 1 1 Screw Top cover Spring Piston gasket Piston Shaft gasket Media shaft Nut Body O-ring Bottom cover Nut Orifice sleeve Support ring Carrier pipe O-ring Rubber ring Nut Rev. 2 Page 19

20 Rev. 2 Page 20

21 5.2 Vacuum filter unit P2 The vacuum filter system P2 can only be used in combination with the cyclone dust collector model 4. If the vacuum filter system is used without a high performance pre-separator for collecting the greater part of the dust particles, the filter cartridges and vacuum blower will be damaged. The collection barrel of the cyclone may never be more than half full. This is necessary in order to let the dust particles fall down easily. When the barrel is filled for more than half, the dust particles will not fall down deep enough and will be sucked into the filter unit. This causes a quick pollution of the cartridge filters. It is NOT ALLOWED to place a bag inside the barrel. A bag would be sucked against the top of the cyclone and the dust particles will go directly to the filter unit. The dust collection system has a vacuum blower which operates at 380 VAC, 3 phase current. This vacuum blower has a power of 1.2 kw. The maximum capacity is 1800 m 3 /hr and a maximum vacuum pressure of 3.2 kpa (abs.) To separate the small dust particles, that have passed the cyclone, two cartridge filters are mounted in an elevator box. The filter cartridges have a surface of 10 m 2 each made of a polyester membrane. Vacuum blower Filter cover Knob screws Filter cartridge The cleaning of these filters is performed by an air pressure reverse pulse. The inlet air is connected on the rear side of the elevator box. The air goes through a manifold which holds a pressure regulator, a compressed-air filter and a pressure gauge. The pressure must be adjusted between 4 and 5 bar. Exceeding the maximum reverse pulse pressure of 5 bar will cause permanent damage to the filter. Dust collection bag The cleaning is performed when the two single point timers get a 220 VAC signal from the cabinet. These timers open the magnetic valves for the reverse pulse cleaning. The timers are adjusted at its minimum interval time of 0.5 min. and have a pulse duration of 100 ms. Because of the reverse pulse the dust gets loose from the filter surface and falls into the dust collection bag. Make sure that the filter cover is always closed during operation and that the knob screws are fastened tightly. Rev. 2 Page 21

22 5.3 Cabinet model 2100C The cabinet has been designed to clean anilox rolls or cylindrical objects which have a diameter between 100 and 200 mm. The face length of the roll has to be bigger than 400 mm and less or equal than 1800 mm. The total roll length may not be greater than 2100 mm. The maximum weight that may be put into the cabinet is 300 kg. All rolls or cylindrical objects may not have any protuberances while the roll is placed on the wheels of both shafts. One of the shafts is driven by an electric motor. A worm gear reducer is mounted between the motor and drive shaft. The rotation speed cannot be adjusted. During operation a nozzle blasts BicarBlast powder on the roll surface while the roll rotates and the nozzle moves along the roll. The nozzle is mounted on a traverse system which has an adjustable speed. The traverse speed is adjustable to cover the blasted roll surface of one revolution. In order to blast rolls with homogenous powder coverage the value for the diameter of the roll needs to be adjusted. The nozzle is positioned at a reference point on the right side when the cabinet is not operative. Before blasting, when all settings are made, the nozzle travels to the reference point when it s not already there. After a completed cycle or when the stop button is pressed the nozzle always travels back to the reference point on the right side. For operation the cabinet only needs 380 Volt, three phase 380V plus zero and protective ground. When the power is turned on a PLC controls all parts of the cabinet. These parts are the traverse system, rotation of the roll and the door lock. The number of passes for the cleaning cycle is programmable. Separate equipment as the powder delivery and suction unit are controlled by the PLC with a start and stop signal. The adjustments needed for operation need to be made manually for this separate equipment. For electrical system drawings see the appendix. Rev. 2 Page 22

23 6. Maintenance Always disconnect the electric power and compressed air supply to the installation when any kind of maintenance or internal inspection to the components of the BioJet installation is performed. Make sure that the compressed air supply is disconnected and the system is depressurised by opening the tank vent. Disconnect the plug from the electrical point on the bottom of the control panel of the cabinet. 6.1 Maintenance for the pressure delivery unit MS-60 Daily maintenance of the pressure delivery unit MS-60: 1. Check the powder level in the pressure vessel by looking in the vessel before pressurising the vessel. 2. Open the compressed air filter before connecting compressed air to the system and let moisture and grease flow out. Close the filter afterwards. 3. Check the blast hose connection before blasting and make sure that it is secured. 4. Always check the systems for any leaks or loose connections. Monthly maintenance of the pressure delivery unit MS-60: 1. Check the gaskets and membranes of the pneumatic blast valve and replace them when necessary. 2. Check the pressure vessel and its piping for leaks. Check also the piping of the vacuum filter unit that is connected to compressed air. If so, replace the leaking parts of the units. 3. Check the quality of the tubes and replace them when necessary. 4. Check the silencer of the pressure vessel for obstruction by blast powder. Disconnect the silencer and clean it when necessary. 5. The inlet air filter is maintenance-free but needs to be checked any way for obstructions. Therefore we advise you to open and clean the filter every month. Rev. 2 Page 23

24 6.2 Maintenance for the filter vacuum unit P2. Daily maintenance of the filter vacuum unit P2: 1. Check the contents of the cyclone dust collection barrel. Empty the barrel with two persons when it is more than half filled. Use the proper breathing and eye protection when the cyclone dust collection barrel is opened. 2. Check the contents of the dust collection bag under the elevators box. Empty the bag when it is filled for 2/3. Use the proper breathing and eye protection when the bag is removed from the elevator box. 3. Always readout the differential pressure on the pressure gauge on the right side of the elevator box. When the pressure is greater than 15 cm of water read the troubleshooting for instructions. Weekly maintenance of the vacuum filter unit P2: 1. Remove the front panel from the elevator box and inspect the filter cartridges for any damages or wear. Replace the filter cartridges after 6 months. 2. Clean the filters when needed. 3. Check the adjusted pressure of the reverse pulse cleaning on the rear side of the P2 vacuum filter. The correct pressure is between 4 and 5 bar. Monthly maintenance of the vacuum filter unit P2: 1. Check piping for any damages or corrosion. Rev. 2 Page 24

25 6.3 Maintenance for the cabinet model 2100C. Daily maintenance of the cabinet: 1. Check the blast hose before blasting and make sure that it is secured. 2. Always check the systems for any leaks or loose connections. 3. Keep your work space and cabinet free from dust and dirt!! Monthly maintenance of the cabinet: 1. Check the quality of the blast and suction hoses and replaces them when necessary. 2. Check the plastic blocks which keep the roll from drifting inside the cabinet. When the blocks are less than 10 mm thick they have to be replaced with new once. You can order them as part number C The cabinet needs no lubrication or any other mechanical maintenance. Never clean the cabinet without using proper breathing- and eye protection and never use any liquids to clean the cabinet. Rev. 2 Page 25

26 7. Troubleshooting Always disconnect the electrical power and compressed air supply to the installation when any kind of maintenance or internal inspection to the components of the BioJet installation is performed. Make sure that the compressed air supply is disconnected and the system is depressurised by opening the tank vent. Disconnect the plug from the electrical point on the bottom of the control panel of the cabinet. 7.1 Troubleshooting for the pressure delivery unit MS The pressure delivery unit MS-60 does not react at start-up of the blast cycle. The pressure delivery unit is not pressurised. Check if the unit is connected to the compressed air and if the inlet air valve is opened. Make sure the pressure regulator is turned open. Make sure the tank vent is closed. (photo 1, page 12) No control signal is given to the pressure delivery unit. Check if the air control hose is connected to the cabinet and the pressure delivery unit. (photo 1, page 12) The blast air does not flow. Check if the choke valve and the media control valve are opened. (photo 2, page 12) The pneumatic blast valve is out of order. Please check the membrane and replace the membrane when necessary. 2. The pressure delivery unit MS-60 depressurizes slower than before. The silencer is polluted with blasting media. Release the silencer and clean it. 3. The nozzle keeps blasting after the blast cycle is stopped. The pneumatic blast valve refuses to close. Close the inlet air valve and disconnect the air supply. Depressurize the vessel and clean the piping with compressed air. Open the pneumatic blast valve and clean it. Check if the O- ring or spring of the pneumatic blast valve are worn. (page 14) 4. The pop-up valve remains closed after depressurizing the vessel. The upper valve guide is polluted with powder. Clean the upper valve guide and the pop-up valve and pop-up gasket. (page 15) 5. The pressure cannot be adjusted at the recommended pressure. The tank vent is open, close the tank vent. (photo 1, page 12) The tank pressure is adjusted higher than 3.5 bar so that the safety valve is opened. The recommended tank pressure is 2.8 bar. (photo 1, page 12) The pressure regulator is polluted. Open the pressure regulator and clean it, replace worn parts of the regulator. (page 18) Rev. 2 Page 26

27 6. The pressure needs to be adjusted during blasting. The compressed air supply has not enough capacity. A compressor capacity of 1.2 m3/min (8.8 kw) is required. An internal diameter of 1/2 for the air hose is recommended. In case of too few capacity adjust the tank pressure at a lower value. 7. The pop-up valve does not close the vessel properly. Remove all obstructions between the pop-up gasket and the pop-up valve head when the vessel is depressurized. Replace these parts when worn. (page 15) 8. The nozzle blasts no or not enough powder. The pressure vessel is empty. Fill the vessel up with powder as described on page 9. Check the powder level by opening the check valve. (photo 2, page 12) There is a blockade somewhere in the powder flow. Shut the choke valve 3 or 4 times for a moment to pump the blockade through the piping. If this has no effect, the carrier pipe or the orifice sleeve probably are obstructed. (page 19) Open the powder release valve and clean the mentioned components. Rev. 2 Page 27

28 7.2 Troubleshooting for the vacuum filter unit P2. 1. The blower and motor won t start. Check if the wiring of the 380 VAC connector on the bottom of the control panel of the cabinet corresponds to the wiring of your electrical points. Do not change the wiring in the connectors of the blower. Remove the side panel of the control panel on the cabinet when the power supply is disconnected. Check the motor security TH2. Press the button on TH2 indicated with 1. Check the fuses F1(36), F2(37) and F3(38). Disconnect the power supply to the cabinet if the side panel of the control panel is opened. 2. The blower moves air in the wrong way. Change two 380 V poles of the 380 VAC connector under the control panel of the cabinet. First disconnect the power supply to the cabinet. (page 8) 3. The blower and motor start but fail afterwards. Remove the side panel of the control panel on the cabinet when the power supply is disconnected. Check the motor security TH2. Press the button on TH2 indicated with 1. The front panel of the P2 vacuum filter unit is not mounted or properly closed. The dust collection bag under the elevator box is not mounted tight on the pipe under the box. Make sure that the system only sucks air from the cabinet and not from the surroundings. 4. Much more noise or vibrations of the blower than normally. Blower propeller is out of balance by powder growth on the blades. Clean the propeller blades. The blower propeller has worn blades and is out of balance. Replace the propeller. The bearings are worn, replace the bearings. 5. The outlet air of the vacuum blower contains dust. The filters are wrong or have not been installed properly. Check if the cartridges have been installed with the proper gaskets. The filter is damaged. Replace the filter by an original filter cartridge. An original filter without damages has a life-time of 2000 hours of operation. Rev. 2 Page 28

29 6. Insufficient air flow The blower operates in the opposite direction. Check if the wiring of the 380 VAC connector on the bottom of the control panel of the cabinet corresponds to the wiring of your electrical points. Do not change the wiring in the connectors of the blower. The blower sucks air from its surroundings. Check if the front panel of the elevator box and the collection bag are properly mounted. Also check the hoses and the cyclone for leaks. Make sure that the outlet piping of the blower is not obstructed. Read out the differential pressure on the pressure gauge on the right side of the elevator box. If the gauge indicates more than 15 cm during operation, then the filter is heavily polluted. If the filter is worn replace the filter. Also check the inlet pressure for the reverse pulse cleaning is adjusted between 4 and 5 bar. The collection bag under the elevator box is full. Empty the bag and place it back tight to the pipe. 7. The reverse pulse cleaning fails. The diaphragm valves fail. Check the diaphragm valves for air leaks. Disconnect the air supply and depressurize the P2 vacuum filter unit. Check the valves for wear or diaphragm failure. Also check if there are any damages or leaks in the electromagnetic valves. Replace all parts that are damaged. 8. The timers for reverse pulse cleaning fail. Check the settings of the timers the correct settings are a interval period of 0.5 min and a pulse duration of 100 ms. Check the wiring of the timers for any damages. Rev. 2 Page 29

30 7.3 Troubleshooting for the cabinet model 2100C. 1. The system cannot be switched on. See if the 380 V connector is plugged in. Remove the 380 V plug from the connector so the cabinet is powerless. remove the side panel of the control panel. Check the fuses F1(36), F2(37) and F3 (38) and replace them if necessary. Never use a fuse with another value than the old one. 2. The system is switched on but does not perform a blast cycle. See if the door is closed properly. See if the emergency stop is pressed. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the fuses F1(36), F2(37), F3 (38), F4 (39) and F5(40) and replace them if necessary. Never use a fuse with another value than the old one. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the motor protection switches TH1, TH2 and TH3 and press the red 1 on each one of them if necessary. 3. The rolls do not turn during a blast cycle. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the motor protection switch TH3 and press the red 1 if necessary. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the fuses F1(36), F2(37), F3 (38), F4 (39) and F5(40) and replace them if necessary. Never use a fuse with another value than the old one. 4. The nozzle does not move during a blast cycle. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the motor protection switch TH1 and press the red 1 if necessary. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the fuses F1(36), F2(37), F3 (38), F4 (39) and F5(40) and replace them if necessary. Never use a fuse with another value than the old one. 5. The vacuum blower does not work during a blast cycle. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the motor protection switch TH2 and press the red 1 if necessary. Remove the 380 V plug from the connector so the cabinet is powerless. Remove the side panel of the control panel. Check the fuses F1(36), F2(37), F3 (38), F4 (39) and F5(40) and replace them if necessary. Never use a fuse with another value than the old one. Rev. 2 Page 30

31 Appendix 1 TüV Manufacturer s Certificate Rev. 2 Page 31

32 Appendix 2 Electrical system drawing and drawings for the position of the components Rev. 2 Page 32