Zero BNP 162 User manual

NOTICE TO PURCHASERS AND USERS OF OUR
PRODUCTS AND THIS INFORMATIONAL MATERIAL
Clemco proudly provides products for the abrasive blast industry
and is confident that industry professionals will use their knowledge
and expertise for the safe and efficient use of these products.
The products described in this material, and the information
relating to these products, are intended for knowledgeable,
experienced users. It is the responsibility of the user to insure that
proper training of operators has been performed and a safe work
environment is provided.
No representation is intended or made as to the suitability of the
products described here for any purpose or application, or to the
efficiency, production rate, or useful life of these products. All
estimates regarding production rates or finishes are the
responsibility of the user and must be derived solely from the user’s
experience and expertise, not from information contained in this
material.
It is possible that the products described in this material may be
combined with other products by the user for purposes determined
solely by the user. No representations are intended or made as to
the suitability of or engineering balance of or compliance with
regulations or standard practice of any such combination of products
or components the user may employ.
This equipment is only one component of a cabinet blasting
operation. Other products, such as air compressors, air filters and
receivers, abrasives, equipment for ventilating, dehumidifying, or
other equipment, even if offered by Clemco, may have been
manufactured or supplied by others. The information Clemco
provides is intended to support the products Clemco manufactures.
Users must contact each manufacturer and supplier of products
used in the blast operation for warnings, information, training, and
instruction relating to the proper and safe use of their equipment.
BNP 162, 164, and 166
Tumble Blast Cabinets
O. M. 14429
DATE OF ISSUE: 07/90
REVISION: F, 08/17
© 2017 CLEMCO INDUSTRIES CORP.
One Cable Car Dr.
Washington, MO 63090
Phone [phone]
Fax [phone]
Email: [email protected]
www.clemcoindustries.com

BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 1
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 14429 Rev. F
1.0 INTRODUCTION
1.1 Scope of Manual
1.1.1 These instructions cover set-up, operation,
maintenance, troubleshooting, optional accessories, and
replacement parts for BNP 160's series suction type
tumble blast cabinets. The instructions cover the
operation of all pull-thru reclaimers and the installation of
the dust collector. One of the following supplemental
manuals is provided with the dust collector Refer to the
appropriate manual for operation and maintenance of
the collector.
CDC-1 Dust collectors ...............manual stock no. 28225
RPC-2 Dust collector .................manual stock no. 22788
RPH Dust collectors ..................manual stock no. 21449
1.1.2 The instructions 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.
1.2 Safety Alerts
1.2.1 Clemco uses safety alert signal words, based on
ANSI Z535.4-2011, 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:
This is the safety alert symbol. It is
used to alert you to potential physical
injury hazards. Obey all safety
messages that follow this symbol to
avoid possible injury or death.
NOTICE
Notice indicates information that is considered
important, but not hazard-related, if not
avoided, could result in property damage.
CAUTION
Caution indicates a hazardous situation that,
if not avoided, could result in minor or
moderate injury.
WARNING
Warning indicates a hazardous situation that,
if not avoided, could result in death or serious
injury.
Danger indicates a hazardous situation that, if
not avoided, will result in death or serious
injury.
1.3 Table of Contents
SUBJECT SECTION LOCATION
INTRODUCTION ........................................................1.0
Scope of Manual ........................................................1.1
Safety Alerts ...............................................................1.2
Table of Contents .......................................................1.3
General Description ....................................................1.4
Theory of Operation ...................................................1.5
Dust Collector Options ...............................................1.6
Nozzle Options ...........................................................1.7
Media ..........................................................................1.8
Compressed Air Requirements ..................................1.9
Electrical Requirements ...........................................1.10
INSTALLATION ..........................................................2.0
General Installation Notes ...........................................2.1
Level Cabinet Enclosure .............................................2.2
Connect Conveying Hose ............................................2.3
Connect Compressed air supply Line(s) .....................2.4
Ground Cabinet ...........................................................2.5
Connect Electrical Service ..........................................2.6
Attach Drain to Filter ....................................................2.7
FIELD INSTALLED ACCESSORIES .........................3.0
OPERATION ...............................................................4.0
Control Panel Operation ..............................................4.1
Media Loading and Unloading ....................................4.2
Loading and Unloading Parts ......................................4.3
Blasting Operation .......................................................4.4
Stop Blasting ...............................................................4.5
ADJUSTMENTS .........................................................5.0
Blasting Pressure ........................................................5.1
Gun Rack Blast Angle .................................................5.2
Media/Air Mixture .........................................................5.3
Reclaimer Static Pressure ...........................................5.4
Optional Externally Adjustable Vortex Cylinder ...........5.5
Door Interlocks ............................................................5.6
Tumble Barrel Slider Doors .........................................5.7
Timer, Blast Duration ...................................................5.8
Speed Control, Barrel (variable speed pkg only) ........5.9
Optional Manometer ..................................................5.10
DANGER

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© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 14429 Rev. F
Preventive Maintenance ...........................................6.0
Daily Maintenance .......................................................6.1
Weekly Maintenance ...................................................6.2
Monthly Maintenance ..................................................6.3
Service Maintenance .................................................7.0
Gun and Nozzle Assembly ..........................................7.1
Media Hose .................................................................7.2
Gear Reducer ..............................................................7.3
Bearing Lubrication .....................................................7.4
Reclaimer Wear Plate Replacement ...........................7.5
Replacing/Installing Reclaimer Liners .........................7.6
Troubleshooting ........................................................8.0
Dust leaking from cabinet enclosure ...........................8.1
Abnormally high media consumption ..........................8.2
Reduction in blast cleaning rate ..................................8.3
Plugged nozzle ............................................................8.4
Media bridging .............................................................8.5
No media or air comes out the nozzle
during blast cycle .....................................................8.6
Blockage in media hose ..............................................8.7
Media surge .................................................................8.8
Poor suction in media hose .........................................8.9
Air only (no abrasive) from nozzle .............................8.10
Media buildup in cabinet hopper, media does
not convey to reclaimer ..........................................8.11
Static shocks .............................................................8.12
Dust leaking from dust collector ................................8.13
Accessories and Replacement Parts
Optional Accessories ..................................................9.1
Electrical Components ............Refer to Elect. Schematic
Cabinet and Barrel Assembly ......................................9.3
Gun and Rack Assembly .............................................9.4
Drive Mechanism .........................................................9.5
Media Metering Assemblies ........................................9.6
Plumbing Assembly .....................................................9.7
Reclaimer Assemblies .................................................9.8
Reclaimer Liners, Rubber ...........................................9.9
300 and 600 CFM Reclaimer Replacement Parts ......9.10
900 CFM Reclaimer Replacement Parts ..................9.11
1.4 General Description
1.4.1 BNP tumble cabinets are intended for blasting
batches of small parts, using fixed nozzles and a rotating
barrel. The cabinet system consist of three major
components:
1. Cabinet Enclosure
2. Reclaimer
3. Dust Collector
1.4.2 Cabinet Enclosure: This manual covers the
three standard BNP tumble cabinet sizes.
The load capacity of the barrel depends on the model.
Standard cabinets are supplied as follows:
MODEL BNP-162 BNP-164 BNP-166
No. of Guns two four six
Max. volume 1 cu. ft. 2 cu. ft. 3 cu. ft.
Max. weight 100 lbs. 200 lbs. 300 lbs.
Reclaimer cfm 300 or 600 600 or 900 900
1.4.3 Reclaimer: The reclaimer is a pull-thru style,
adjustable, cyclone separator, into which air, dust, fines,
and by-products generated by the blasting process are
drawn from cabinet enclosure for separation. The
reclaimer size is determined by the cabinet size; therefore,
reclaimer sizes are not interchangeable. 300 cfm and 600
cfm reclaimers are attached to the back of the cabinet
enclosure; 900 cfm reclaimers are freestanding.
1.4.4 Dust Collector: All dust collectors used with
these tumble cabinets are pull-thru, reverse-pulse type
cartridge collectors. Dust and fines drawn from the
reclaimer are collected on the outer surface of the filter
cartridge. Refer to dust collector options in Section 1.6.
1.4.4.1 Refer to Figure 1 for arrangement of
components with a CDC-1 dust collector. The model
shown is a 164 with a 600 cfm reclaimer. Figure 2
shows a freestanding 900 cfm reclaimer connected to
an RPC-2 reverse-pulse dust collector. The optional
RPH-2 (600 cfm and 900 cfm) is set up the same way as
the RPC, but includes a hopper for additional dust
storage, and empties into a drum. The overall height of
the RPH is approximately 10-feet, 6-inches, and 12-ft
when the top access door is open. An upgraded, RPC or
RPH collector may be added at any time.
1.5 Theory of Operation
1.5.1 Once the components are correctly setup and
parts are loaded into the barrel, the air supply and
exhauster are turned ON and the cabinet door is closed.
The cabinet is readied for operation by setting the timer
on a constant speed control panel or by pulling the
sequence switch on a variable speed control panel.
Starting the timer causes air to flow through the blast
guns. Air moving through the guns draws media into the
blast gun mixing chamber. The media mixes with the air
and propels out the nozzles. As the barrel rotates, the
parts tumble in the blast stream until all parts and
surfaces are uniformly cleaned. Some of the blast media
remains in the barrel to cushion the parts as they tumble.
A portion of the blast media, along with fines, dust, and
by-products generated by blasting, flows through the
adjustable slide gates into the cabinet hopper. These
particles are drawn into the reclaimer for separation.
Lightweight dust and fines are drawn out to the dust
collector. Heavier reusable media fall through the screen
into the reclaimer hopper for reuse. The dust collector
traps dust and fines and discharges clean air. Blasting
automatically stops when the timed cycle is completed.

BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 3
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 14429 Rev. F
Figure 1
1.6 Reverse Pulse Dust Collector Options
WARNING
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.
Identify all materials that are to be removed by
blasting. Use reverse-pulse dust collectors with
HEPA after-filters if lead coating or any other
toxic materials are being removed by the
blasting process.
1.6.1 CDC-1 Dust Collectors: Shown in Figure 1, this
collector is available in 300, 600, and 900 cfm models.
The single filter cartridge is cleaned by using a manually-
controlled pulse of compressed air. Dust collects in a 5-
gallon dust drum, which must be frequently emptied.
Refer to manual number 28225.
1.6.2 RPC-2 Dust Collectors: Shown in Figure 2, this
collector is available in 600 cfm and 900 cfm models.
Dual filter cartridges are automatically cleaned by a
timed, periodic pulse of compressed air. Dust collects in
the drawer, and it must be frequently emptied. Refer to
manual number 22788.
Figure 2
Some items are rotated for clarity
* Vortex is standard when cabinet is provided with RPC
or RPH dust collector
Metering Valve
Media Hose
Debris Screen
Reclaimer
Dust Container
Damper
Pilot Pressure-Regulator
Air Filter, Compressed air inlet
Pilot-Operated
Pressure-Regulator
Tumble Barrel Door Interlock
Actuator
Control Panel
Variable speed shown
Parts Tray
Blast-Gun Rack
Guard, Drive Mechanism
Air Inlet Ducts
CDC-1
Dust Collector
Media Manifold
Fill Door
Duct
Inlet
RPC-2Dust Collector
Dust Collector Damper
Dust Drawer
*Adjustable
Vortex

BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 4
© 2017 CLEMCO INDUSTRIES CORP. www.clemcoindustries.com Manual No. 14429 Rev. F
1.6.3 RPH-2 Dust Collector: The RPH-2 is available
in 600 cfm and 900 cfm models. It is set up and operates
the same as the RPC-2 as shown in Figure 2, but
instead of a dust drawer, the collector sits atop a hopper,
which provides additional dust storage, and empties into
a 30-gallon drum. Refer to manual number 21449.
1.6.4 HEPA (high-efficiency particulate air) Filter:
HEPA after-filters provide additional filtration and must
be used with a reverse-pulse cartridge collector when
removing lead coatings or any other toxic materials.
1.7 Nozzle Options
1.7.1 Ventilation requirements limit standard cabinets to
5/16" nozzle and No. 5 (5/32" orifice) air jets. In some
applications, where compressed air is limited, No. 4 (1/8"
orifice) air jets may be used, but blasting rates will
decrease accordingly. Refer to Section 1.9 for
compressed air requirements. Unless otherwise specified
at the time of order, cabinets are supplied with durable
boron carbide nozzles. Optional ceramic and tungsten
carbide nozzles are available for use with nonaggressive
media, and are shown under Accessories and
Replacement Parts in Sections 9.1 and 9.4. Use boron
carbide nozzles when blasting with aggressive media,
such as those listed in Section 1.8.4.
1.8 Media
WARNING
Obtain Safety Data Sheets (SDS) for the blast
abrasive. Abrasive blasting with sands
containing crystalline (free) silica can lead to
serious or fatal respiratory disease. As NIOSH
recommends, do not use abrasives containing
more than trace amounts (more than one
percent) free silica.
NOTE: Use only abrasives specifically manufactured for
blast cleaning which are compatible with the surface being
blasted. Abrasive produced for other applications may be
inconsistent in size and shape, contain particles that could
jam the abrasive metering valve, or cause irregular wear.
1.8.1 ZERO tumble blast cabinets utilize most
common reusable media 30-mesh to 180-mesh, that is
specifically manufactured for dry blasting (glass bead
and aluminum oxide are most commonly used). Media
sizes shown (listed under media headings) are for
guidelines only. The guidelines are based on standard
nozzle size and average conditions, such as blast
pressure, media/air mixture, visibility inside the cabinet,
humidity, and reclaimer cleaning rate.
Several factors affecting the reclaimer cleaning-rate
include: reclaimer size (cfm), contamination of parts
being blasted, media friability, damper setting (static
pressure), and dust collector filter loading (differential
pressure across the filter cartridge(s).
Media finer than those recommended may increase
carryover to the dust collector. Media coarser than those
recommended may be too dense for the reclaimer to
recover from the cabinet hopper.
1.8.2 Steel: Steel grit or shot should not be used with
standard tumble cabinets. Steel is too heavy to recover
large amount of media delivered from multiple blast
guns.
1.8.3 Sand and Slag: Sand should NEVER be used for
abrasive blasting because of the respiratory hazards
associated with media containing free silica. Slags are not
recommended because they rapidly breakdown and are
not recyclable, making them unsuitable for cabinet
applications.
1.8.4 Silicon Carbide, Aluminum Oxide, and
Garnet: These are the most aggressive of the
commonly-used media. Aggressive media may be used,
but the service life of any components exposed to the
media will be reduced. To avoid unscheduled down time,
periodically inspect the reclaimer wear plate, blast hose,
and nozzle for wear.
When using aggressive media use a fully-rubber-lined
reclaimer. NOTE Rubber-lined reclaimers are available as
factory-installed items and can be field installed on
reclaimers if they have removable tops and designed to
accept liners. Refer to Section 9.9.
1.8.5 Glass Bead: Most beads are treated to ensure
free-flow operation even in environments of moderately
high humidity. Glass beads subjected to excessive
moisture may be reused only after thorough drying and
breaking up any clumps.
1.8.6 Lightweight and Fine-mesh Media: When
using lightweight (such as agricultural) media or fine
mesh (between 120 and 180 mesh.) media, the optional
adjustable vortex cylinder may help retain media. NOTE:
The adjustable vortex cylinder is standard on systems
using an RPC-2 or RPH-2 dust collector.
When using 180-mesh and finer media, the reclaimer
inlet baffle may need to be removed to retain media and
avoid carryover. Baffle removal and replacement is
easily accomplished on reclaimer models with bolt-on
removable tops. Reclaimers with welded-on tops require
grinding to remove the baffle and once it is removed, it
cannot be replaced.