Clemco ZERO DCM-161 User manual

DCM 161 MINI TUMBLE
BLAST CABINET
Clemco Industries Corp. •One Cable Car Drive •Washington, MO 63090
Phone: [phone] •Fax: [phone]
Email: [e-mail]
www.clemcoindustries.com
NOTICE TO PURCHASERS AND USERS OF OUR PRODUCTS
AND THIS INFORMATIONAL MATERIAL
The products described in this material, and the information relating to
those products, is intended for knowledgeable, experienced users of
abrasive blasting equipment.
No representation is intended or made as to the suitability of the products
described herein for any particular purpose of application. No represen-
tations are intended or made as to the efficiency, production rate, or the
useful life of the products described herein. Any estimate regarding
production rates or production finishes are the responsibility of the user
and must be derived solely from the user’s experience and expertise, and
must not be based on information in this material.
The products described in this material may be combined by the user in a
variety of ways for purposes determined solely by the user. No
representations are intended or made as to the suitability or engineering
balance of the combination of products determined by the user in his
selection, nor as to the compliance with regulations or standard practice
of such combinations of components or products.
It is the responsibility of the knowledgeable, experienced users of the
products mentioned in this material to familiarize themselves with the
appropriate laws, regulations and safe practices that apply to these
products, equipment that is connected to these products, and materials
that may be used with these products.
It is the responsibility of the user to insure that proper training of
operators has been performed and a safe work environment is provided.
Our company is proud to provide a variety of products to the abrasive
blasting industry, and we have confidence that the professionals in our
industry will utilize their knowledge and expertise in the safe efficient use
of these products.
OWNER’S MANUAL
© CLEMCO INDUSTRIES CORP. 2002 •Stock No.: 14408 •Manual No.: 883-0489 •Date of Issue: , Rev. C, 07/02

DCM-161 MINI TUMBLE BLAST CABINET Page 1
1.0 INTRODUCTION DANGER
Danger indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
1.1 Scope of Manual
1.1.1 These instructions cover set-up, operation,
maintenance, troubleshooting, optional accessories, and
replacement parts for The DCM-161 Mini tumble blast
cabinet.
1.3 General Description
1.1.2 These instructions also contain important
information required for safe operation of the cabinet.
Before using this equipment, all personnel associated
with the blast cabinet operation must read this entire
manual, and all accessory manuals to become familiar
with the operation, parts, and terminology.
1.3.1The DCM-161 tumble cabinet blasts small batches
of parts, using a fixed nozzle and rotating barrel. See
Figure 1 for arrangement and call outs of primary
components.
1.3.2The maximum capacity of the barrel is 25 lbs.
1.3.3 The cabinet requires approximately 17 cfm of
compressed air at a maximum of 60 psi.
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-1998, to alert the user of a potentially
hazardous situation that may be encountered while
operating this equipment. ANSI's definitions of the signal
words are as follows:
1.4 Theory of Operation
1.4.1 When parts are loaded into the barrel, the air
supply and exhauster are turned "on", and the cabinet door
is closed, the cabinet is ready for operation by engaging the
timer located on the lower front of the cabinet enclosure.
Starting the timer causes air to flow through the fixed blast
gun mounted through the cabinet door. Air moving through
the gun draws media into the blast gun mixing chamber.
The media mixes with the air and is propelled out the
nozzle. As the barrel rotates, the parts tumble in the blast
stream ensuring that all parts and surfaces are uniformly
cleaned. The blast media flows through the perforated
drum and into the cabinet hopper for reuse. Dust and fines
are drawn through the exhauster and trapped in the dust
bag. Blasting automatically stops when the timed cycle is
completed.
This is the safety alert symbol. It is used to
alert the user of this equipment of potential
personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
CAUTION
Caution used without the safety alert symbol
indicates a potentially hazardous situation
which, if not avoided, may result in property
damage.
1.5 Dust Collection
1.5.1 The DCM-161 dust bag is not suitable for use in
applications which generate dust from lead coatings,
heavy metals or any other toxic materials.
Caution indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
CAUTION
Warning indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
Prolonged exposure to any dust could result in
serious lung disease and death. Short term
ingestion of toxic materials, such as lead dust
or dust from other heavy metals and corrosives,
could cause serious respiratory injury or death.
This machine is not to be used in applications
which generate dust from lead coatings, heavy
metals or any other toxic materials. Identify all
materials that are to be removed by blasting.
WARNING
WARNING

DCM-161 MINI TUMBLE BLAST CABINET Page 2
Tumble Barrel
Door Interlock Switch
Blast Nozzle
Filter Ba
g
Air inlet port.
Must be kept open
Exhauste
r
Media Drain Plu
g
Blast Gun Air Hose
Door Interlock Bracket
Air Filter/Regulator
Compressed air inlet
Timer Control
Media Hose
Figure 1
1.6 Nozzle Options
1.6.1 Ventilation requirements limit standard cabinets
to 5/16" nozzle and No. 4 (1/8" orifice) air jet. Unless
otherwise specified at the time of order, cabinets are
supplied with a ceramic nozzle. More durable tungsten
carbide and boron carbide nozzles are available and are
shown under Accessories and Replacement Parts in
Sections 7.1 and 7.3. Use boron carbide nozzles when
blasting with aggressive media such as those listed in
Section 1.8.4.
1.7 Tumble Barrel Options
1.7.1 Standard barrels are perforated with 3/16" holes.
An optional barrel with 1/16" holes is available for use
with fine abrasive or applications that produce small
chips or other byproducts that could plug the blast
nozzle. See Section 7.1.
1.8 Media
1.8.1 DCM-161 utilizes most common reusable media
30 mesh to 180 mesh, that is specifically manufactured
for dry blasting. Media finer than those recommended
may carryover to the dust bag. Media coarser than those
recommended may not convey through the media hose.
Media life can be extended by mixing the media in the
hopper after each cycle.
1.8.2 Steel: Steel grit 50 mesh and finer or shot up to
170 may be used.
1.8.3 Sand and Slag: Sand should never be used
because of the hazards of using media containing free
silica. Slags are not recommended because they rapidly
break down.
1.8.4 Aluminum Oxide, Silicon Carbide, and
Garnet: Aggressive media such as these may be used
but consideration should be given to accelerated wear
on all parts of the cabinet, barrel, nozzle and hoses,
which come in contact with the media. When these
media are used extensively, use boron nozzles.
1.8.5 Glass Bead: Most beads are treated to ensure
free-flow operation even under moderately high humidity
conditions. Glass beads subjected to excessive moisture
may be reused after thorough drying and breaking up of
any lumps.

DCM-161 MINI TUMBLE BLAST CABINET Page 3
1.8.6 Fine-mesh Media: In most cases media finer
than 180 will carryover to the dust bag.
1.8.7 Lightweight Media: In most cases plastic
media and most agricultural media are not
recommended with the tumble cabinet. They are usually
too light for suction blast applications, and may bridge in
the barrel and hopper.
1.9 Compressed Air Requirements
1.9.1 Compressed air consumption for the cabinet is
approximately 17 cfm at 60 psi.
1.9.2 The filter/regulator at the air inlet connection,
reduces condensed water from the compressed air. Its
use is especially important in areas of high humidity, or
when fine-mesh media are used. Moisture causes media
to clot and inhibits free flow through the feed assembly.
If moisture problems persist, an air dryer may be
required.
1.10 Electrical Requirements
1.10.1 The system requires 115-VAC, 1-Ph, 60-Hz,
with 15 Amps service. A power cord is supplied. No
additional wiring is required.
Do not use electrical adaptors that eliminate the
ground prong on 115 volt plugs. Doing so can
cause injury from electric shock, and
equipment damage.
2.0 INSTALLATION
2.1 General Installation Notes
2.1.1 Place the cabinet in a convenient location where
compressed air and electrical service are available.
Allow full access to the door and service areas. Leave
enough clearance around the dust bag for it to inflate
without interference.
2.2 Connect Compressed Air Supply Line
2.2.1 Install an isolation valve at the air source to
enable depressurization for service. Connect a 1/2 inch
or larger air line from the air source to the air
filter/regulator.
If twist-on type air hose couplings are used,
they must be secured by safety pins or wires to
prevent accidental disconnection while under
pressure. Hose disconnection while under
pressure could cause serious injury.
WARNING
2.3 To prevent static electricity build up, attach an
external grounded wire from an earth ground to the
grounding lug on the rear of the cabinet.
2.4 Attach the dust bag to the exhauster outlet.
Secure using the clamp provided.
2.5. Plug the cabinet power cord into a grounded,
115 volt outlet.
3.0 OPERATION
3.1. Control Functions
3.1.1. Timer: Sets duration of the blast cycle and
starts the blasting. Blasting automatically stops when the
timer times out.
WARNING 3.1.2 Door Interlock: When the door is open the blast
gun is disengaged, preventing blasting.
3.2 Media Loading and Unloading
3.2.1 Media Loading: With the timer off, add clean
dry media, by pouring it through the front door. Maximum
media capacity is approximately 1/10 cu. ft. (3 quarts).
Do not overfill.
3.2.2 Media Unloading: To empty the cabinet of
spent media, turn off the exhauster and place an empty
container under the media drain plug. Unscrew the plug,
and tilt the cabinet as needed for media to flow into the
container. If media doesn't flow, it has caked. Open the
fill door and stir media until it starts to flow. Replace the
plug when empty.
3.2.3 Use a vacuum and thoroughly purge the cabinet
of media when changing media type, especially when
changing from coarse media to fine, or when changing
from hard media to soft.

DCM-161 MINI TUMBLE BLAST CABINET Page 4
3.4.5 Start the blast cycle by setting the timer for the
blast duration. Blasting begins as soon as the timer is
set.
3.3 Loading and Unloading Parts
3.3.1 Parts must be free of oil, water, grease, or other
contaminants that will cause media to clump or
contaminate parts.
3.3.2 Load parts directly into the tumble barrel. Do not
overload the barrel; maximum load should not exceed 25
lb., or the lower edge of the retainer as shown in Figure
2.
Figure 2
3.3.3 Close the cabinet door. Be certain door is
latched securely, or door interlock system will prevent
blasting.
3.4 Blasting Operation
•Keep door closed during blasting.
•Stop blasting immediately if dust leaks are
detected.
3.4.1 Slowly open the air valve on the air supply hose
to the cabinet. Check for air leaks on the initial start up,
and periodically thereafter.
3.4.2 Adjust the pressure regulator (filter/regulator)
located on the side of the cabinet, to the required blast
pressure per Section 4.1.
3.4.3 Load media and parts.
3.4.4 Close door and latch securely.
Shut down the cabinet immediately if dust
discharges from the cabinet or filter bag. Make
sure that the bag is clamped securely over the
exhauster outlet, and that it is not worn or
damaged. Prolonged breathing of any dust
could result in serious lung disease. Short term
ingestion of toxic dust such as lead, poses an
immediate danger to health. Toxicity and health
risk vary with type of media and dust generated
by blasting. Identify all material being removed
by blasting, and obtain a material safety data
sheet for the blast media.
WARNING
Do not load parts
above the bottom
rim of the retainer.
Tumble Barrel
Retainer
3.4.6 Check media flow per Section 4.3.
3.5 Stop Blasting
3.5.1 Blasting, and barrel rotation, and the exhauster
stop when the timer cycle is complete.
3.5.2 Open the door only enough to disengage the
door interlock, and turn the timer on. Let it run for several
seconds to clear airborne dust, then turn the switch off.
3.5.3 Remove parts and check blast coverage.
3.5.4 When finished, shut off the air supply valve,
drain the air filter.
CAUTION
4.0 ADJUSTMENTS
4.1 Blasting Pressure
4.1.1 The filter/regulator, enables the user to adjust
blasting pressure to suit the application. The maximum
recommended pressure is 60 psi. Lower pressures may
be used for delicate work. Higher pressure may cause
dust or media to escape from the cabinet.
4.1.2 To adjust, unlock the knob, and turn it clockwise
to increase pressure or counter-clockwise to decrease
pressure. Pressure will usually drop from closed-line
pressure when blasting starts. Once operating pressure
is set, lock the knob to maintain the setting.

DCM-161 MINI TUMBLE BLAST CABINET Page 5
4.2 Timer
4.4 Door Interlock, Figure 4
4.2.1 Set the timer for the duration of the blast cycle.
Blasting automatically stops when the timer times out.
Trial and error will determine the timer setting for the
most favorable results. After the part is correctly
processed, make a note of the total blast time for future
runs of similar parts.
4.3 Media/Air Mixture, Figure 3
4.3.1 Observe media flow through the clear media
hose. Media should flow smoothly and evenly through the
hose.
4.3.2 If the air exiting the nozzle pulses or if media does
not flow smoothly, the metering valve requires adjusting.
To adjust: loosen the locking nut, and adjust the metering
screw until the upper holes in the metering stem are
closed-off, and the lower holes are fully open. See Figure
3. This adjustment is a starting point.
Figure 3
4.3.3 If pulsation occurs in the media hose, either media
is damp and caked, or not enough air is entering the
media stream. While blasting, loosen the locking nut and
slowly turn the adjusting screw out (counterclockwise
when viewed from the top) until the media flows smoothly.
Tighten the locking nut to maintain the setting.
4.3.4 If media flow is too light, decrease air in the
mixture by turning the metering screw in (clockwise when
viewed from the top) covering more of the holes so less air
enters the media hose. Tighten the locking nut to maintain
the setting.
Never attempt to override the interlock system.
Doing so could result in injury from unexpected
blasting.
WARNING
4.4.1 The door interlock disables the blasting control
circuit when the door is open. To enable blasting, the
door interlock switch must be engaged when the door is
closed. The interlock is set at the factory and does not
usually require field adjustment unless parts are
replaced. When adjustment is required, proceed as
follows.
Figure 4
Adjusting Screw
Adjust the screw to engage
the switch when door is
Cabinet Door
Interlock Switch
Upper holes
fully closed
Locking Nut
Lower holes
fully open
Adjusting Screw
4.4.2 Close cabinet door.
4.4.3 Loosen the adjusting screw nut.
4.4.4 Center the screw on the switch, and turn the
adjusting screw in or out as required to engage the
switch without applying excessive pressure. Tighten the
adjusting screw nut.
4.4.5 Test the operation with the door open only
enough to disengage the interlock switch, and then
again with the door closed. The interlock should stop the
blasting when the door is opened, and permit blasting
when the door is closed.

DCM-161 MINI TUMBLE BLAST CABINET Page 6
5.3.2 From inside the cabinet door, unscrew the
holding nut from the gun end, and pull the nozzle from
the gun. Inspect the nozzle O-ring and replace if worn or
damaged. Insert a new nozzle, placing the tapered end
toward the jet. Screw the holding nut onto the gun.
5.0 MAINTENANCE
This machine is not to be used for applications
which generate dust from lead coatings, heavy
metals or any other toxic materials. Failure to
wear approved respirators and eye protection
when servicing dust-laden areas of the cabinet,
and when emptying the dust bag could result in
serious eye irritation and lung disease. Toxicity
and health risk vary with type of media and dust
generated by blasting. The respirator must be
approved for the type of dust generated.
Identify all material being removed by blasting,
and obtain a material safety data sheet for the
blast media.
WARNING
5.4 Media Hose
5.4.1 To avoid unscheduled down-time, periodically
inspect the media hose for thin spots, by pinching it
every 6 to 12 inches.
5.5 Tumble Barrel
5.5.1 Periodically inspect the barrel for wear. Replace
the barrel as soon as it is worn thin.
NOTE: To avoid unscheduled downtime, establish a
weekly inspection schedule. Inspect all parts subjected
to media contact, including; the gun, nozzle, media hose,
and tumble barrel.
6.0 TROUBLESHOOTING
5.1 Dust Bag
5.1.1 The bag collects dust on its inner surface. A high
dust level in the cabinet indicates a dirty bag. Empty as
frequently as necessary to maintain good air flow
through the cabinet, and before the weight of dust
prevents full inflation of the bag. A zipper opening is
located in the bottom of the bag for emptying.
5.1.2 Periodically turn the bag inside out and vacuum
the inner surface.
NOTE: Blast media is usually non-toxic, however, some
materials removed by the process may be. Check with
proper authorities for disposal restrictions.
5.2 Compressed Air Filter
5.2.1 The cabinet is equipped with a manual drain air
filter/regulator. Drain the filter at least once a day, and
more often if water is present. Moist air inhibits the flow
of media. If moisture continues to be present, a dryer or
after-cooler may be required.
5.3 Nozzle
5.3.1 Replace the nozzle(s) when its diameter has
increased by 1/16", or when suction diminishes
noticeably.
To avoid serious injury, observe the following
when troubleshooting. Turn off the air, and lock
out and tag out the air supply.
WARNING
6.1 Dust Leaking From The Cabinet Enclosure
6.1.1 Dirty filter bag. Empty the dust bag regularly.
See Section 5.1.
6.1.2 Damaged door gaskets. Inspect and replace
damaged gaskets.
6.1.3 Blast pressure too high. Maximum blast
pressure is 60 psi.
6.1.4 Paddle wheel worn. Check wheel for wear.
6.2 Abnormally High Media Consumption
6.2.1 Media may be too fine or worn-out.
6.2.2 Using friable media that rapidly breaks down.
6.2.3 Nozzle pressure too high for the media, causing
media to break down.

DCM-161 MINI TUMBLE BLAST CABINET Page 7
6.3 Reduction In Blast Cleaning Rate
6.3.1 Low media level reducing media flow. Check
and fill if low.
6.3.2 Incorrect metering valve adjustment. Adjust per
Section 4.3.
6.3.3 Reduced air pressure. This may be caused by a
malfunctioning regulator, a dirty filter element in the air
filter, partially closed air valve, leaking air line, or other
air tools in use.
6.3.4 Blockage in media line or gun. See Section 6.8.
6.3.5 Worn gun parts such as nozzle or air jet. Inspect
and replace all worn parts.
6.3.6 Worn media hose. Check hose for leaks and soft
spots. Replace worn or damaged hose.
6.3.7 Moist media. Frequent bridges or blockage in
the area of the metering valve can be caused by
moisture. See Section 6.5.
6.4 Plugged Nozzle
6.4.1 Media mixture too rich. Adjust media/air mixture
per Section 4.3.
6.4.2 Remove nozzle and check for blockage from
foreign material. If the standard tumble barrel allow large
particles to pass and block the nozzle, use the optional
1/16" hole barrel. See Section 7.1.
6.5 Media Bridging
6.5.1 Frequent bridging or blockage in the media
metering valve can be caused by damp media. Media
becomes damp by blasting parts that are slightly oily,
from moisture in the compressed air line, or from
absorption.
6.5.2 To avoid contaminating media from the
workpiece, all parts put into the cabinet should be clean
and dry. If parts are oily or greasy, degrease and dry
them prior to blasting.
6.5.3 Moist compressed air may be due to a faulty
compressor that overheats, or pumps oil or moisture into
the air line, too long an air line permitting moisture to
condense on the inside, and from high humidity. Drain
the air filter and receiver tank regularly. If the problem
persists, it may be necessary to change media more
often, or install an aftercooler or air dryer.
6.5.4 Absorption. Some media tends to absorb
moisture from the air, especially fine-mesh media in high
humidity areas. Empty the media and store it in an
airtight container when cabinet is not in use.
6.6 Neither Media Nor Air Comes Out The Nozzle
When The Blast Cycle is Engaged.
6.6.1 Door interlocks not engaging. Check adjustment
per Section 4.4.
6.6.2 Pressure regulator may be turned down or off.
Check pressure on pilot regulator.
6.6.3 Make sure that the air compressor is on and air
supply valves are open.
6.7 Blockage In Media Hose
6.7.1 Media obstructions. Usually caused when the
media mixture is too rich. Adjust media/air mixture per
Section 4.3.
6.7.2 Wet or damp media. See Section 6.5.
6.8 Media Surge
6.8.1 Heavy media flow. Adjust per Section 4.3.
6.9 Poor Suction In Media Hose
6.9.1 Nozzle is worn. Replace if worn 1/16" or more.
6.9.2 Blockage in media hose or nozzle. See Sec. 6.4.
6.10 Blow-Back Through Media Hose
6.10.1 Blockage in nozzle. Remove the nozzle and
check blockage.
6.10.2 Air jet washer (Fig. 6 item 5) not tightly sealed
against air jet. Tighten the bushing into the gun body.
6.11 Static Shocks
6.11.1 Cabinet not grounded. Abrasive blasting
generates static electricity. The cabinet must be
grounded to prevent static buildup. See Section 2.3.
6.12 Dust Leaking From Dust Bag
6.12.1 Check for damaged or loose fitting dust bag.

DCM-161 MINI TUMBLE BLAST CABINET Page 8
3. Barrel assembly
7.0 ACCESSORIES AND REPLACEMENT PARTS
Standard, with 3/16" diameter holes.......... 12230
Optional, with 1/16" diameter holes........... 18254
7.1 Optional Accessories
4. Motor, 1/2-HP 115-VAC ............................... 12308
5. Paddle wheel, 100 cfm ................................ 12339
Tumble barrel w/ 1/16" holes ................................. 18254
6. Housing, 100 cfm exhauster ........................ 12269
Lock pins (pkg. of 25) for twist-on hose couplings . 11203
7. Gasket, 5/16" x 1" adhesive backed
Nozzles
specify feet required ................................. 00187
boron carbide, No. 5 ........................................ 11935
8. Clamp, 4" ..................................................... 11577
tungsten carbide, No. 5 ................................... 13118
9. Dust bag 12" x 28" ....................................... 11500
10. Switch, push button (door interlock) ............ 12119
11. Timer, 60 min. .............................................. 12180
7.2 Cabinet and barrel Assembly, Figure 5
12. Shaft, barrel drive w/ roll pin & set screw .... 13677
13. Grommet, rubber ......................................... 11798
Item Description Stock No.
14. Bearing, 3/4" bore ........................................ 11521
15. Bracket, drive motor mount .......................... 12812
1. Gasket, door, 7/16" x 1" adhesive backed
16. Motor, speed reduced .................................. 11905
4 feet required ........................................... 00190
17. Gasket, gun mount back plate ..................... 11782
2. Latch, spring ................................................ 12263
18. Plate, gun mount back ................................. 12811
Figure 5
18 17 16 15
14
13
12
11
10
9
8
7
7
6
1
2
3
5
4

DCM-161 MINI TUMBLE BLAST CABINET Page 9
7.3 Gun feed and Plumbing Assembly, Figure 6
Item Description Stock No.
1. Nut, nozzle holding ...................................... 11914
2. Body, gun ..................................................... 12267
3. Air jet No. 4 .................................................. 11951
4. Nozzle
Ceramic No. 5, (standard) ........................ 11930
tungsten carbide, No. 5 ............................ 13118
boron carbide, No. 5 ................................. 11935
5. Washer ......................................................... 04396
6. Nut, 3/4" lock ................................................ 12807
7. Bushing, 3/4" x 3/8" ...................................... 12748
8. Adapter, 3/8 male NPT x 1/2" male flare ..... 11726
9. Fitting, hose, 1/2" barb x 1/2" fem. swivel .... 15002
10. Hose, 1/2" clear media, 3 ft. required .......... 12476
11. Bracket, gun mount ...................................... 12806
12. Solenoid, 1/4" 3-way .................................... 12199
13. Filter/regulator w/ gauge .............................. 11690
14 Gauge, 1/8" cbm (replacement).................... 01908
15. Fitting, hose, 3/8" NPT x 1/2" barb .............. 06369
16. Hose, 1/2" air, 3 ft. required ......................... 12472
17. Grommet, rubber, media hose ..................... 11798
18. Muffler, 1/4" bronze ...................................... 03988
19. Stem, metering adjusting ............................. 23097
20. Screw, metering adjusting ........................... 23098
21. Nut, metering adjusting stem lock ................ 23099
11
94
7 3 21
8 6 5
15
20
13 14
10 21
18
17
19
12
16
15
Figure 6