BNP 162, 164, and 166 Tumble Blast Cabinets O. M

Transcription

1 BNP 162, 164, and 166 Tumble Blast Cabinets O. M DATE OF ISSUE: 07/90 REVISION: F, 08/17 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 CLEMCO INDUSTRIES CORP. One Cable Car Dr. Washington, MO Phone (636) Fax (800) info@clemcoindustries.com 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.

2 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page INTRODUCTION 1.1 Scope of Manual 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 RPC-2 Dust collector... manual stock no RPH Dust collectors... manual stock no 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 Clemco uses safety alert signal words, based on ANSI Z , 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 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 DANGER SECTION LOCATION INTRODUCTION Scope of Manual Safety Alerts Table of Contents General Description Theory of Operation Dust Collector Options Nozzle Options Media Compressed Air Requirements Electrical Requirements INSTALLATION General Installation Notes Level Cabinet Enclosure Connect Conveying Hose Connect Compressed air supply Line(s) Ground Cabinet Connect Electrical Service Attach Drain to Filter FIELD INSTALLED ACCESSORIES OPERATION Control Panel Operation Media Loading and Unloading Loading and Unloading Parts Blasting Operation Stop Blasting ADJUSTMENTS Blasting Pressure Gun Rack Blast Angle Media/Air Mixture Reclaimer Static Pressure Optional Externally Adjustable Vortex Cylinder Door Interlocks Tumble Barrel Slider Doors Timer, Blast Duration Speed Control, Barrel (variable speed pkg only) Optional Manometer

3 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 2 Preventive Maintenance Daily Maintenance Weekly Maintenance Monthly Maintenance Service Maintenance Gun and Nozzle Assembly Media Hose Gear Reducer Bearing Lubrication Reclaimer Wear Plate Replacement Replacing/Installing Reclaimer Liners Troubleshooting Dust leaking from cabinet enclosure Abnormally high media consumption Reduction in blast cleaning rate Plugged nozzle Media bridging No media or air comes out the nozzle during blast cycle Blockage in media hose Media surge Poor suction in media hose Air only (no abrasive) from nozzle Media buildup in cabinet hopper, media does not convey to reclaimer Static shocks Dust leaking from dust collector Accessories and Replacement Parts Optional Accessories Electrical Components... Refer to Elect. Schematic Cabinet and Barrel Assembly Gun and Rack Assembly Drive Mechanism Media Metering Assemblies Plumbing Assembly Reclaimer Assemblies Reclaimer Liners, Rubber and 600 CFM Reclaimer Replacement Parts CFM Reclaimer Replacement Parts General Description 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 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 or 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 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 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 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.

4 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 3 CDC-1 Dust Collector Air Filter, Compressed air inlet Air Inlet Ducts Reclaimer Debris Screen Fill Door Pilot Pressure-Regulator Pilot-Operated Pressure-Regulator Blast-Gun Rack Guard, Drive Mechanism Damper Metering Valve Media Hose Control Panel Variable speed shown Media Manifold Tumble Barrel Door Interlock Actuator Parts Tray Dust Container Some items are rotated for clarity Figure Reverse Pulse Dust Collector Options 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 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 manuallycontrolled pulse of compressed air. Dust collects in a 5- gallon dust drum, which must be frequently emptied. Refer to manual number 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 *Adjustable Vortex Dust Collector Damper RPC-2Dust Collector Dust Drawer Duct Inlet * Vortex is standard when cabinet is provided with RPC or RPH dust collector Figure 2

5 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 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 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 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 Media 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 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 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 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 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 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 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.

6 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page Plastic Media: Plastic and similar lightweight and/or non-aggressive media are generally not recommended for suction-style cabinets because the lower blast velocity of suction blasting combined with the softer and lighter weight media, do not provide the media impact for productive blasting. Best performance from plastic media is achieved with pressure blasting, requiring a pressure vessel with a 60-degree conical bottom. Refer to Clemco s AEROLYTE cabinet line Bicarbonate of Soda: Bicarbonate of soda is not recommended. Bicarb is a one-use media usually used and will quickly saturate the filter cartridge(s). Best performance from bicarb media is achieved with pressure blasting, requiring a pressure vessel. Refer to Clemco s AEROLYTE cabinet line for cabinets that are specifically designed for use with bicarbonate of soda. 1.9 Compressed Air Requirements The size of the compressor required to operate the cabinet depends on the size of air jet*, the number of guns and blasting pressure. Refer to the table in Figure 3 to determine cfm requirements. Consult with a compressor supplier for suggested compressor size based on the air consumption. NOTE: A separate air line is required for the reverse pulse dust collector. Compressed Air Consumption in CFM Model Jet Nozzles CFM PSI 162 *1/8" /32" *1/8" /32" *1/8" / *1/8" jets decrease blast rates by approximately 30%. Figure The air filter at the air inlet connection reduces condensed water from the compressed air. The filter automatically drains when moisture fills the bowl to a certain level. Its use is especially important in areas of high humidity, or when using fine-mesh media. Moisture causes media to clot and inhibits free flow through the feed assembly. If the filter does not remove enough moisture to keep media dry and flowing, it may be necessary to install an air dryer of aftercooler in the air supply line Electrical Requirements All wiring external to the cabinet is provided by the user to comply with local electrical codes Electrical requirements depend on the size and phase of the dust collector exhauster motor and barrel drive motor. Refer to the electrical schematic stowed in the control panel for wiring and amps. Refer to Section 2.6 to connect electrical service. 2.0 INSTALLATION 2.1 General Installation Notes Refer to Figure 1 (and Figure 2 for optional RPC-2 dust collector) for the general arrangement. Place all components in a convenient location where compressed air and electrical service are available. The cabinet location must comply with OSHA and local safety codes. Allow for full access to all doors and service areas, and for efficient handling of parts. Provide enough clearance at the dust collector to do maintenance and to remove the dust container. Place freestanding reclaimers directly behind the cabinet with flex hose connections and metering valves facing toward the cabinet with as few bends as possible. Determine the best location for all components and position them before making compressed air connections, electrical connections, and attaching flex hose. 2.2 Level Cabinet Enclosure Level the cabinet by using shims as necessary under cabinet corners. A cabinet that is not level may have problems with door closing and barrel tracking. 2.3 Connect Conveying Hose Connect the smaller diameter flex hose between the cabinet hopper pipe adaptor and reclaimer inlet adaptor, and connect the larger diameter hose between the reclaimer outlet and dust collector inlet. It is easier to slip the hose over the adaptors and create a tighter seal if the first two or three inches of wire are removed from the inside of the hose. Use care not to damage the hose. Clamp flex hose securely in position with worm clamps provided. NOTE: The hose wire helps dissipate static electricity in the conveying hose, and helps ground each

7 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 6 segment. In order for the hose wire to dissipate static electricity, the wire must touch the metal of each segment. 2.4 Connect Compressed Air Supply Line(s) Failure to observe the following before connecting the equipment to the compressed air source could cause serious injury from the sudden release of compressed air. Lockout and tagout the compressed air supply. Bleed the compressed air supply line. To avoid the risk of injury from compressed air, install an isolation valve and bleed-off valve where the air supply it tapped into the compressed air system. This enables depressurization of the compressed air circuit before performing maintenance Refer to Paragraph to determine the recommended size for the air supply hose, then refer to Figure 4 and apply thread sealant to the male threads of an air fitting that is compatible with the air supply hose fitting, and install it onto the air filter located on the side of the cabinet. NOTE: the style of connection shown in Figure 4 is for reference only. Size the couplings and fittings no smaller than the ID of the air hose. Some items are removed or rotated for clarity. Air Filter Connect an air line from the air source to the air filter inlet. For best blasting performance, size the air line as follows: BNP " ID or larger BNP /4" ID or larger BNP /2" or larger NOTE: A separate air line is required for the optional reverse-pulse dust collector. Hose disconnection while under pressure could cause serious injury or death. Use safety lock pins or safety wire to lock twist-on couplings together and help prevent accidental separation, and safety cables to prevent hose from whipping should separation occur. 2.5 Ground Cabinet 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. 2.6 Connect Electrical Service Shorting electrical components could result in serious electrical shocks, or equipment damage. Electrical power must be locked out and tagged out before performing any electrical work. All electrical work or any work done inside a control panel or junction box must be performed by a qualified electrician, and comply with applicable codes. Air Fitting Lock Pin Air Supply Hose Safety Cable Figure 4 All wiring external to the cabinet is provided by the user to comply with local electrical codes Electrical requirements depend on the size and phase of the dust collector exhauster motor and barrel drive motor. Refer to the electrical schematic stowed inside the control panel for wiring and amps. After wiring is completed, keep a copy of the schematic with the manual for future reference and for electrical replacement parts Voltage (230 or 460) is determined at time of order. Panels are supplied with 230-volt controls unless 460-volt is specified at the time of purchase The electrician provides service from the user s disconnect to the electrical panel mounted on the

8 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 7 cabinet and from the panel to the motor on the dust collectors Observe the warning that follows and check the rotation of the motors. To check, jog the exhauster starter (momentarily turn switch ON and OFF). This will cause the motor to rotate slowly. Look through the slots in the fan housing on top of the motor where rotation of the fan can easily be observed. Proper rotation of the exhauster is indicated by the arrow on the exhauster housing. The fan should rotate toward the scroll outlet. The tumble barrel should rotate clockwise when viewed from the gear reducer side. Do not look into the reclaimer exhauster outlet while the paddle wheel is turning. Injury to the eye or face could occur from objects being ejected from the exhauster Check the dust collector motor amperage on initial start up. If the motor draws excessive amperage, gradually close the damper until the amperage is within the specifications shown on the motor plate. The damper is located on the inlet of CDC dust collectors, and on the exhauster outlet of RPC and RPH dust collectors. 2.7 Attach Drain Tube to Air Filter, Figure Insert a short length of 3/8" OD tubing into the automatic drain at the bottom of the compressed-air filter and place the other end into a pail. When the filter automatically drains, the water will drain into the pail. 3.0 FIELD INSTALLED ACCESSORIES 3.1 Manometer The optional manometer kit is listed in Section Constant static pressure is necessary for precise media separation, as the reclaimer s efficiency is accomplished by a centrifugal balance of particle weight and size. The manometer measures static pressure. Reclaimer static pressure is set by adjusting the dust collector damper. Refer to Section 5.4 to adjust static pressure. Refer to Section 5.10 for instructions on using the manometer. 3.2 Barrel Divider Kit, for BNP 164 and Barrel dividers split the barrel chamber into separate compartments. This permits simultaneous blasting of different parts. Barrels should not be divided into compartments containing less than two nozzles. 4.0 OPERATION 4.1. Control Panel Operation Constant speed controls, Figure 6 Refer to Section for variable speed controls. 1. System Start: Pushing the button starts the exhauster and tumble barrel. Other controls will not operate unless the exhauster is running. 2. System Stop: Pushing in the button stops the exhauster and all other controls. Air Filter Insert tubing into filter drain 5 and place other end into a pail or other container for water Figure 5 1 Figure 6

9 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 8 3. Timer: Sets duration of the blast cycle. Turn the dial to set the blast duration between 1 minute and 60 minutes. Once the timer is set, begin blasting by pushing the "System Start" button. Blasting automatically stops when the timer times-out. The time must be reset after every blast cycle. 4. Barrel Jog: The exhauster must be on to enable the switch. Pressing the momentary switch rotates the barrel. Use it to empty the barrel of residual media that remains in the barrel after blasting and to position the barrel door to the front of the cabinet for loading and unloading parts. The barrel continues to rotate as long as pressure is maintained on the switch Figure 7 5. Door Interlock: The door interlock disables blasting when the door is open. To enable blasting, the door must be closed and the door interlock switch engaged Variable speed controls, Figure 7 Refer to Section for constant speed controls. 1. System Start: Pushing the button starts the exhauster and tumble barrel. Other controls will not operate unless the exhauster is running. 2. System Stop: Pushing in the button stops the exhauster and all other controls. 3. Timer: Turn the dial to set the blast duration between 1 minute and 60 minutes. Once the timer is set, begin blasting by pushing the "Sequence Start" button. Blasting automatically stops when the timer times-out. Once the timer is set it does not require resetting after blasting, unless the blasting duration changes. 4. Barrel Jog: The exhauster must be on before engaging the switch. Pressing the momentary switch rotates the barrel. The barrel continues to rotate as long as pressure is maintained on the switch. 5. Door Interlock: The door interlock disables blasting when the door is open. To enable blasting, the door must be closed and the door interlock switch engaged. 6. Sequence Start: Once the timer is set (the timer does not require resetting unless the blasting duration changes) and the gun switch is ON, blasting starts when the switch is pushed in. If the gun switch is OFF, all tumble operations except blasting starts when the system switch is engaged. 7. Sequence Stop: Pushing the button stops the blast and tumble cycle. If the timed cycle was not completed, the blast cycle will continue for the remaining time if the sequence start button is pressed. 8. Blast Guns Switch: The switch engages and disengages the blast guns. If the switch is toward ON, blasting starts when the system start button is pressed. If the switch is OFF, all tumble operations except blasting are ON. NOTE: The barrel with continue to rotate, which will empty abrasive from within the barrel. Do not turn the blast guns OFF during the blast cycle if it will cause part-on-part damage occurring while tumbling. 9. Speed Control: Controls the rotation speed of the tumble barrel. Optional Media Blow-off: A blow-off timer is situated inside the variable speed panel, but it does not operate any controls unless the blow-off option was requested when the cabinet was ordered. If the cabinet includes the option, blow-off automatically begins at the end of the blast cycle. Adjust the timer to the length of time the blow-off is to remain ON. Blow-off automatically stops at the end of the timed cycle. If media remains in the barrel or on the parts after the cycle, increase blow-off time. NOTE: If the blow-off option was not requested, set the timer to 0 and leave it there. Because the timer is included and wired into the circuit, the blow off option may be added later. Refer to the wiring schematic stowed inside the panel.

10 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page Media Loading and Unloading Media Loading: With the exhauster OFF, add clean dry media, by pouring it through the reclaimer fill door. Do not fill above the cone on the reclaimer. Do not pour media directly into the cabinet hopper, as overfilling may occur. Overfilling will result in media carryover to the dust collector and possible blockage in the conveying hose. Refill only after all media has been recovered from the cabinet. The approximate amount of media to charge the system is as follows: 300 CFM Reclaimer Lbs. (.5 cu. ft.) Media 600 CFM Reclaimer Lbs. (.75 cu. ft.) Media 900 CFM Reclaimer Lbs. (1 cu. ft.) Media Media Unloading: To empty the cabinet and reclaimer of media, recover all media from the cabinet, turn OFF the exhauster and place an empty container under the metering valve manifold (or metering valve on 162 units). Unscrew the plastic plug, permitting media to flow into the container. If media does not flow, it has caked. Open the fill door and stir media until it starts to flow. Replace the plug when the reclaimer is empty. 4.3 Loading and Unloading Parts Open the cabinet door, and pull the exhauster button switch to start the exhauster. Press the barrel jog button until the barrel-loading door is facing forward Unlatch the barrel door clamps and remove the door Parts must be free of oil, water, grease, or other contaminants that will cause media to clump, or clog filters Load parts through the barrel door. Do not overload the barrel. The following table shows maximum load capacity in weight and cubic feet. MODEL BNP-162 BNP-164 BNP-166 Max. volume 1 cu ft. 2 cu. ft. 3 cu. ft. Max. weight 100 lbs. 200 lbs. 300 lbs Check gun rack blast-angle per Section Close the barrel door and latch it securely Close the cabinet door and make sure it is latched securely. Door interlock system will prevent blasting if door is not closed. 4.4 Blasting Operation CAUTION Always close cabinet, reclaimer and dust collector doors before blasting. Keep all doors closed during blasting. After blasting, keep doors closed and exhauster on until the cabinet is clear of all airborne dust. Stop blasting immediately if dust leaks are detected 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 Turn ON the exhauster by pulling the exhauster button Adjust the pilot pressure regulator located on the upper, left side of the cabinet, to the required blast pressure per Section For variable speed electrical package only, set timer blast duration Start the blast cycle as follows: Constant Speed Electrical Package: 1. Set timer for blast duration. Blasting begins when timer is set. Variable Speed Electrical Package: 1. Set Speed Control 2. Pull Gun Switch ON 3. Pull Sequence Switch ON Shut down the cabinet immediately if dust discharges from the cabinet or dust collector. Make sure that the filter cartridge(s) are correctly seated and not worn or damaged. Prolonged breathing of any dust could result in serious lung disease or death. 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 SDS safety data sheet for the blast media Check media flow per Section 5.3.

11 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page Stop Blasting Blasting and barrel rotation stop when the timer cycle is complete Allow exhauster to run awhile before opening the door; do not turn off exhauster until parts are unloaded Press the barrel jog button until the barrelloading door is facing forward, then completely remove the barrel door Unloaded parts through the barrel door, or jog the barrel until parts empty into the parts tray Remove parts from the tray. The parts tray may be installed with the open end toward the front or back, place it to most easily handle the parts Reload the barrel, or shut off the air supply valve, drain the air filter, and switch OFF the exhauster. 5.0 ADJUSTMENTS 5.1 Blasting Pressure, Figure The pilot regulator, located on the upper left side of the cabinet, enables the user to adjust blast pressure to suit the application. The suitable pressure for most purposes is about 80 psi. Lower pressures may be required on delicate substrates, and will reduce media breakdown. Higher pressure may be required for difficult blasting jobs on durable substrates. If pressure is too high, suction in media hose will decrease, and if high enough, cause blow-back in the hose. In all cases, optimal production can only be achieved when pressure is carefully monitored To adjust, unlock the knob, and turn it clockwise to increase pressure or counterclockwise to decrease pressure. Pressure will usually drop from closed-line pressure when blasting starts. Once operating pressure is reached, lock the knob to maintain the setting 5.2 Gun Rack Blast Angle, Figure 9 NOTICE The gun rack must be adjusted to direct the blast stream toward the parts. If the rack is not correctly adjusted, the tumble barrel will wear prematurely and parts will require longer blast cycles Load parts into the barrel; close the barrel door; and jog the barrel until it has rotated one revolution. This places the parts at the angle in which they tumble Open the door and check the alignment of the guns by placing a dowel, pencil, or similar object into a nozzle If the guns do not point toward the center of the parts, loosen the three gun rack hold-down brackets and rotate the rack until the nozzles point to the center of the parts Remove the dowel and tighten the hold-down brackets to maintain the setting. Loosen all three holddown brackets. Pull knob out to unlock Turn knob clockwise to increase pressure Turn knob Counterclockwise to decrease pressure Push knob in to lock and maintain setting Figure 8 Rotate gun rack until nozzle (blast stream) is pointed toward the center of the parts. Figure 9

12 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page Media/Air Mixture, Figure Media should flow smoothly and evenly through the hoses. Flow can be observed through the clear metering valve body If media does not flow smoothly, 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. Refer to Figure 10. This adjustment is a starting point. Upper holes fully closed Adjusting Screw Locking nut Figure 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 finger-tight to maintain the setting 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 finger-tight to maintain the setting. 5.4 Reclaimer Static Pressure Lower holes fully open Correct static pressure varies with size of reclaimer and the size, weight and type of media Adjust static pressure by opening (handle inline with air flow) or closing (handle perpendicular to air flow) the dust collector damper. Refer to the dust collector owner s manual; the damper is located on the inlet on CDC-1 dust collectors, and on the exhauster outlet on RPC and RPH dust collectors. If the damper is not opened far enough, the reclaimer will not remove fines, resulting in dusty media, poor visibility, and possible media blockage in the conveying hose. If the damper is opened too far, it may cause carryover (usable media carried into the dust collector) and result in excessive media consumption. Open only as far as necessary to obtain a balance of dust removal without media carryover A manometer is useful when adjusting or monitoring static pressure. The manometer kit is listed under Optional Accessories in Section 9.1. Refer to Section 5.10 for manometer operation. The following are static pressure starting points for given media. Static pressure may need to be lower with finer media, higher with coarser media. Run the media through several blast cycles allowing the reclaimer to function with these settings. Inspect the media in the reclaimer and fines in the dust collector as noted in Paragraph Continue adjusting static pressure until optimum media cleaning without carryover is attained. Glass Bead No. 4 to " to 3-1/2" Glass Bead No. 8 to /2-3" Alox. 60 & coarser " Alox. 80 & finer /2-3" If the damper has been adjusted and carryover or excessive dust in the media continues, an optional adjustable vortex cylinder, (standard on pull through reclaimers), may help retain media. This option is usually required only when using 200 mesh and finer media, or lightweight media. See Section 5.5, and reclaimer accessories in Section 9.10 (600 cfm) or 9.11 (900 cfm). 5.5 Optional Externally-Adjustable Vortex Cylinder Figure 11, Not available for 300 cfm reclaimer NOTE: The externally-adjustable vortex is an option when the cabinet is provided with a CDC-1 Dust collector. The vortex is standard with 600 cfm and 900 cfm reclaimers when the cabinet is provided from the factory with an RPC or RPH dust collector. The vortex cylinder fine-tunes media separation. Before adjusting the cylinder, adjust the damper on the dust collector to increase or decrease static pressure per Section 5.4. Once the damper is adjusted, adjust the cylinder The vortex cylinder is located atop the reclaimer where the flex hose connects. Adjustments are made by loosening the handle's tensioning knob and moving the handle to achieve the correct setting. When the correct setting is established, tighten the locking knob to prevent movement. Start with the lever slightly to the right (about one o clock as shown in Figure 11) of the vertical position To Remove More Fines: (Too much dust in media) Raise the cylinder by moving the lever left toward "COARSE", in 1/4" increments at the indicator plate. Allow the media to go through several blast cycles before determining if further adjustment is needed.

13 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page To Remove Less Fines: (Excessive usable media is carried to the dust collector) Lower the vortex cylinder by moving the lever right toward "FINE", in 1/4" increments at the indicator plate. NOTE: If the cylinder is lowered too far, the reclaimer will again begin to allow usable media to be carried over, and cause abnormally high static pressure When using media finer than 180-mesh, the inlet baffle of the reclaimer may need to be removed. Refer to Section Control Panel Interlock Switch Adjusting Screw Nut Loosen, and move sideways to center the adjusting screw on the interlock switch. Adjusting Screw Adjust the screw to engage the switch when door is closed. Bracket Remove more fines from media by moving the handle farther to the left Remove less fines by moving the handle farther to the right Tensioning Knob Bracket Screws Loosen the bracket screws, and move the bracket up or down to center the adjusting screw on the interlock switch. Cabinet Door Figure Door Interlocks, Figure 12 Figure 11 Never attempt to override the interlock system. Doing so could result in injury from unexpected blasting 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 Close cabinet door 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. NOTE: Negative pressure inside the cabinet may cause the door to flex inward. Tests should be performed with the exhauster running. 5.7 Tumble Barrel Slide Doors, Figure The barrel must retain an amount of media to cushion parts as they tumble. The two slide doors control the amount of media retained in the barrel. Slide door to widen or narrow the openings as required to retain media cushion Loosen the actuator bracket screws and adjusting screw nut. Move the actuator bracket up or down, and the adjusting screw sideways, to center the adjusting screw on the switch button. Tighten the bracket screws Turn the adjusting screw in or out as required to engage the switch without applying excessive pressure on it. Tighten the adjusting screw nuts. Figure 13

14 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page How far the slide doors are open depend, on the parts and media size. Begin with the door set to allow a small amount of media to fall through the holes as the barrel turns After a short blast cycle, open the barrel-loading door to see how much media is retained in the barrel and if the parts are nicked from part-on-part impingement. Adjust the opening size accordingly. 5.8 Timer, Blast Duration Refer to Section for constant speed controls Refer to Section for variable speed controls 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 Timers in constant-speed electrical panels require resetting after each cycle. The variable speed timer does not require resetting unless the blasting duration changes. 5.9 Speed Control, Barrel: Refer to Section Available with variable speed electrical package only Set the speed control to rotate the barrel for optimum speed for processing the parts. Trial and error will determine the optimum speed setting. If multiple types of parts are processed using different speeds, make a NOTE: of the speed for future runs of similar parts Optional Manometer NOTE: These instructions show several methods of taking static pressure readings (negative pressure) on Pulsar reclaimers, by using a flexible tube manometer. Use the method best suited for the application. The instruction explains the processes for taking periodic readings and shows how to permanently install the manometer for taking frequent readings. Permanent fittings should be installed when the manometer installation is permanent. Use silicone sealer or other sealant to seal around the fitting to prevent leaks. The fitting should be capable of being capped when the manometer tube is removed. This will prevent leaks that alter the reclaimer s separation efficiency. Taking readings at different locations could produce different readings. Static pressure readings at the door are generally.5" to 1" lower than those taken above the reclaimer. The readings are reference points, so readings should be taken using the same method each time the reading is taken Refer to instructions packed with the manometer for preparation and operating of the manometer Connect one end of the 3/16" ID tubing to one of the tubing connectors (elbow) at the top of the manometer by pushing it over the barbed adaptor Leave the needle protector on the needle and insert the needle into the other end of the tubing. The ends of the tubing must fit tight on the manometer and needle; leaks will give inaccurate readings Open both manometer valves (elbows) per the instructions provided with the manometer Magnets on the manometer hold it in position on the reclaimer body. The manometer must be verticallyplumb so the fluid is level on both sides Needle placement: The illustration in Figure 14 shows the manometer set-up for taking both periodic and frequent static pressure readings Taking readings in the flex hose: Remove the needle protector, and insert the needle into the flex hose approximately 8" from the top of the reclaimer Taking readings at the reclaimer door: Open the reclaimer fill door, remove the needle protector, and place the needle so the point is inside the door opening. Carefully close the door on the needle. The side of the needle will embed into the rubber, creating an airtight seal Taking frequent readings using a permanent fitting: A permanent fitting may be installed in the reclaimer wall as shown in Figure 14 for taking frequent static pressure readings. Permanent fittings must have a barb to accommodate the 3/16" ID tubing and have a means of sealing the fitting when the manometer is not in use. Use silicone sealer or other sealant to seal around the fitting to prevent leaks. The fitting should be capable of being capped when the manometer tube is removed. Sealing the fitting will prevent leaks that alter the reclaimer s separation efficiency. Air drawn into the reclaimer will cause carryover of good media to the dust collector.

15 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page 14 Refer to Paragraph Insert the needle into straight section of flex hose, about 8- inches above the top of the reclaimer. 8 The manometer must be vertical when taking pressure readings. With the exhauster OFF, slide the rule to align the zero with the fluid level. Refer to Paragraph Place the needle so the point is inside the door opening. Carefully close the door on the needle. Refer to Paragraph For taking frequent readings, install a permanent fitting in the reclaimer wall, just below the inner cone as shown. To obtain the pressure reading: With the exhauster ON, add the number of inches the fluid travels up the column, to the inches the fluid travels down the other column. The total is the static pressure reading. Reclaimers are for reference and may differ from those shown. Figure 14 In the example shown, fluid traveled up the right column 1-3/4 inch, and down the left column 1-3/4 inch. Static pressure is determined by adding the columns together. In the example, the static pressure is 3-1/2 inches Adjust the slide rule to align the zero with the fluid level. Refer to Figure Turn the exhauster ON. The negative (static) pressure will move fluid in the tube. NOTE: Readings must be taken with the cabinet doors open, and with the exhauster running To find the static pressure, add the number of inches the fluid travels up one column to the inches the fluid travels down the other column. Refer to the example in Figure 15. Figure After the taking the readings, replace the needle protector. Close the manometer valves and store the manometer in the original container in a clean area. NOTE: If the manometer installation is permanent, the manometer may remain on the reclaimer body after the valves are closed.

16 BNP 162, 164 and 166 TUMBLE BLAST CABINETS Page PREVENTIVE MAINTENANCE NOTE: To avoid unscheduled downtime, establish a weekly inspection schedule. Inspect all parts subjected to media contact, including: the gun, nozzles, media hose, flex hose, reclaimer wear plate, in addition to all items covered in this section. 6.1 Daily Maintenance Check media level in reclaimer and refill as necessary. 6.1,2 Check reclaimer screen for debris. The screen is accessible through the reclaimer door. With the exhauster OFF, remove the screen and empty it daily or when loading media. Empty the screen more often if part blasted causes excessive debris. Do not operate the machine without the screen in place, oversized byproduct from blasting could plug the nozzle Moist air inhibits the flow of abrasive. Empty the compressed-air filter drain container. The cabinet is equipped with an auto-drain air filter. By inserting a short length of 3/8" O.D. tubing into the automatic drain at the bottom of the filter and placing the other end into a pail, the filter automatically drains the water into the pail. Empty the pail at least daily and while it is manageable. NOTE: If the filter does not remove enough moisture to keep abrasive dry and flowing, it may be necessary to install an air dryer or aftercooler in the compressed-air supply line Refer to the dust collector owner s manual and empty dust containers. Adjust intervals based on filling rate. 6.2 Weekly Maintenance Inspect nozzles and gun bodies for wear as noted in Section 7.1, Replace nozzle when orifice diameter is worn 1/16" larger than original size, or when suction diminishes noticeably During operation, inspect cabinet door seals for media leaks Inspect flex hoses for wear Inspect the media hose for thin spots, by pinching it every 6 to 12 inches. Replace the hose when it becomes soft. 6.3 Monthly Maintenance Inspect reclaimer wear plate or rubber liners for wear. Replace as necessary Inspect reclaimer door gasket for wear or damage Inspect the barrel liners for wear. Replace the liners as soon as the rubber is worn to the metal substrate 6.4 Dust Collector Reverse-pulse dust collectors are covered in a separate manual. Refer to Section Refer to the dust collector owner s manual and drain the pulse manifold at the end of each shift Refer to the CDC-1 dust collector manual for pulsing instructions; pulse the cartridge at least every half hour of blasting and before turning OFF the exhauster. Dusty blasting conditions will require more frequent pulsing. Alternate RPC and RPH dust collectors are automatically pulsed at timed intervals.