Contracor DBS-100RCS User manual

CONTRACOR GmbH
42329 Wuppertal
Germany
Art. 10406/10411
Abrasive Blasting Machines DBS-100RCS, DBS-200RCS
OPERATING MANUAL
Version 2.5
E
DE
RU
Sandstrahlmaschinen DBS-100RCS, DBS-200RCS
BEDIENUNGSANLEITUNG
Version 2.5
Seite 20.
Аппараты абразивоструйные
DBS-100RCS, DBS-200RCS
РУК В ДСТВ П ЭКСПЛУАТАЦИИ
Версия 2.5
стр. 38.

2CONTRACOR
®
Version 2.5
Contents
1. Safety 3
2. Package and description 4
3. Set-up, operation and shut-down 6
4. Abrasive blasting operations 8
5. Maintenance 10
6. Troubleshooting 11
7. SpeciÀcation 13
8. Instructions for Use Pressure Vessel of
Abrasive Blasting Machine CO TRACOR DBS 15
ATTENTION!
READ A D FULLY U DERSTA D THIS MA UAL BEFORE STARTI G WORK.
THE FOLLOWI G I FORMATIO IS IMPORTA T FOR SAFETY A D HEALTH OF
OPERATOR A D PERSO EL I VICI ITY.
ATTENTION!
BUYI G THE MACHI E, PLEASE, REQUEST TO FILL I THE GUARA TEE CARD
CORRECTLY!
FAILURE TO PRODUCE A FILLED-I FORM WILL MAKE YOUR GUARA TEE
I VALID.

3
CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
1. Safety.
ATTENTION!
SAFETY MEASURES FOR ABRASIVE BLASTI G.
1. You must wear protective equipment: a helmet with positive
ai feed, b eathing ai Àlte , p otection suit, leathe gloves, and
special footwear.
2. Do not use worn or damaged equipment during operation.
3. Point the nozzle only at the area to be cleaned.
4. Use only dry well-sieved abrasive materials, appropriate for
abrasive blasting operations.
5. All personnel without protection equipment should be outside the
zone of blasting operations.
6. Before starting abrasive blasting operations you must:
— Ensure that hoses and Àttings are not worn;
— Fixhose couplings with wire;
— Ensure that air is fed to the helmet;
— Ensure that pressurizingvalve is in correct position;
— Ensure that the machine is in steadystate position

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2. Package and description.

5
CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
Fig. 2.1.
1 —cover,
2 —screen,
3 —machine tank,
4 —RChoseTWINLINE,
5 —Remote control unit RCV,
6 —moisture and oil separator
CAF-1,
7 —abrasive blastinghose
UNIFLEX,
8 —operator helmet COMFORT,
9 —nozzleholder,
10 —nozzle,
11 —RChandle DMH,
12 —breathing air hose,
13 —breath air Àlter BAF-1,
14 —safetyball valve.
2.1. Package.
Table. 2.1.
Order code Model Description, package
10406 DBS-100RCS Abrasive BlastingMachine, 100 L,
screen,
cover,
moistureand oil separator Àlter CAF-1,
remote control unit RCV,
remote control handle DMH,
meteringvalve SGV,
twin hosein RCTWINLINE20m,
Àttingset for RChose.
10411 DBS-200RCS Abrasive BlastingMachine, 200l,
screen, cover,
moistureand oil separator Àlter CAF-1,
remote control unit RCV,
remote control handle DMH,
meteringvalve SGV,
RCtwin hose TWINLINE20m,
Àttingset for RChose.
10970 RCV Remote control valve (5, Fig.2.1)
10880 DMH Remote control handle (11, Fig.2.1)
12103 TWINLINE Remote control twin hose, d=6mm, roll 40 m
(4, Fig.2.1)

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Version 2.5
3. Set- p, operation and sh t-down.
3.1. Preparation for operation.
For remote control system start up you should follow these instructions:
1. If necessary shorten the RChose to the length of the used blastinghose.
2. Connect the Àttings provided in the package with RChose. Connect RChose to
distant control handle DMHfrom one side and TWINLINEline of the blastingmachine
from another side.
ATTENTION!
DO OT TIGHTE U IO S TOO MUCH, I PARTICULAR THE U IO S OF RC
HA DLE. IT CA DAMAGE SOME COMPO E TS A D CAUSE A AIR LEAK.
3. Ensure that all connectionsare leak-proof.
4. Ensure that all connectionson the RCvalve and RChandle DMHare connected
properly, and according to the color. Transverse joint will make the system non-
operational.
5. Fix RChandle DMHto the blasting hose, usingclamp bands right behind the nozzle
holder.
6. We recommend to connect a twin hose Twinline to the blasting hose usingclamp
bands every1.5 m.

CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
ATTENTION!
ALWAYS USE A OIL-MOISTURE SEPARATOR WHE USI G REMOTE
CO TROL SYSTEM TO PREVE T WEAR O RC VALVE.
BESIDES, A OIL-MOISTURE SEPARATOR OPTIMIZES ABRASIVE BLASTI G
OPERATIO S.
7. Ensure that compressor is positioned out of the abrasive blastingoperations zone on
downwind side.
8. Start compressor and increase pressure and temperature up to operational values.
9. Open the ball valve at machine compressed air line (the handle of the open valve
should be parallel to the compressed air line).
10. Open the safetyball valve 14 (Fig.2.1).
11. Close meteringvalve SGVbyrotatingthe handle clockwise.
12. Connect compressed air hose to hose coupling of the machine. Compressed air hose
diameter should beat least 1.1/4". Lock hose couplingwith a safetyclip or wire.
13. Connect abrasive blastinghose to hose coupling of the machine. Lock hose coupling
with a safetyclip or wire.
14. Fill the machine tank with abrasive.
15. Put protective equipment on.

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Version 2.5
4. Abrasive blasting operations.
4.1. Start up.
1. Check all connections from compressor to the nozzle to ensure that theyare properly
Àxed (badlyÀxed air hose of the compressor cause a serious damage).
2. Ensure that abrasive blastingmachine is Àlled with abrasive.
3. Ensure that the necessarysafetymeasures for you and others are observed:
— protective equipment is used,
— puriÀed air is fed to the helmet.
4. Always check positionof RChandlelever, which should be in the safetyposition with
the holder in vertical position
5. Feed compressed air to the machine intake.
ATTENTION!
MACHI E MAXIMUM OPERATI G PRESSURE — 10 bar.
6. Close both ball valves at the RCvalve.
7. Ensure that there is no leak in the system. Air should come ONLYout of the vent
under the RChandle lever.

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CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
4.2. Abrasive blasting operations.
ATTENTION!
DURI G A BREAK I OPERATIO ALWAYS OPE SAFETY BALL VALVE 14 (Fig.
2.1) AT RC VALVE, OVER AGAI ST THE BLUE LI E OF TWI HOSE (TWI LI E).
RC HA DLE LEVER SHOULD BE EVER FIXED I OPERATIO POSITIO .
SUCH FIXI G MAY CAUSE A SERIOUS I JURE.
1. Turn the holder on RChandle and press the lever (start up). Thetank is pressurized.
Onlycompressed air is expelled from the nozzle.
2. Adjust meteringvalve SGVto provide optimal air-abrasive mixture. The general rule for
abrasive blasting operations: the less abrasive you use, the better.
3. To stop operation you should release the lever (the holder automaticallyreturns to its
initial position).
4.3. Shut-down abrasive blasting operations.
1. Remove the remains of abrasive from the tank. To do this disconnect the nozzle and
point the hose into a suitable container for the abrasive remains. Turn the holder on
the RChandle and press the lever.
2. If upon completion of operation themachine is left outside youshould cover it with
plastic Àlm to avoid ingress of moisture into the tank.
ATTENTION!
AT START UP A D SHUT DOW ALWAYS CHECK FOR PRESE CE OF WATER
I THE SGV VALVE BY OPE I G THE UPPER BALL VALVE (Fig. 7.1). IF A
LARGE AMOU T OF WATER IS PRESE T, CHECK THE FILTER CAF-3.

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Version 2.5
5. Maintenance.
5.1. Machine maintenance.
Pressurizing valve replacement.
Open the inspection door of the machine to get access to the pressurizing valve.
Screw out the guide tube with the valve inside. Install a newvalve and screwthe guide tube
back into its place.
Pressurizing valve ring replacement.
The ringis replaced trough the machine Àlling oriÀce. Pull out the old ring, put a new
ringinto the groove and press it heavilyto correct position.
ATTENTION!
USE O LY ABRASIVE MATERIALS, APPROPRIATE FOR ABRASIVE BLASTI G
OPERATIO S.
EVER USE WET U SIFTED ABRASIVE MATERIALS.
5.2. Daily maintenance.
1. Check thecontrol valve for water presence. If water is present, check theCAF-3 Àlter
state.
2. Ensure that therubber insert of the RChandleis in proper condition.If theylook bad
or are worn, replace them, to avoid possible damage.
3. Ensure that hosesand Àttings are not worn; and properlyÀxed.
5.3. Monthly maintenance
(or after every 160 operation hours).
1. Ensure that the mufÁer and its pipeare in proper condition.
2. Ensure that there is no leak in all air connections.

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CONTRACOR
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DBS-100 RCS, DBS-200RCSArt. 10406/10411
3. Dismantle the control valve following RCV operation manual and check all moving
parts. If they look worn, replace them, to avoid possible damage. Assemble the
valve and lubricate its moving parts with general purpose lube oil.
6. Tro bleshooting.
Choking.
If neither abrasive, nor air comes out of the nozzle, relieve pressure and depressurize
themachine,then ensure that thenozzle is not choked. If onlyair without anyabrasive
comes out of the nozzle, fullyopen the meteringvalve, and then quicklyclose and open
again the lower ball valve of the line. If these actions do not help to relieve the pressure in
the machine, open the inspection door and ensure that there is no foreign matter in the
tank (stones, paper, etc.).
Abrasive surges.
Duringstart-up of the machine abrasive surges are normal to a certain degree.
However id abrasive surges continue, you should stabilize theabrasive Áow byquick closing
and opening of the line lower ball valve. Abrasivesurges often result from elevated moisture
content in compressed air system.Installationof additional moisture and oil separator can
solve this problem.
Wet abrasive removal.
To remove wet abrasive from machine tank you should disconnect the blasting
hose and remove rubber gaskets at machinehose coupling. Then you must fullyopen the
metering valve and close the lower ball valve in the machine compressed air line. With such
valve conÀguration compressed air will onlyenter the machine tank and press wet abrasive
out of the tank.
6.1. RC system troubleshooting.
The followinglist of checks can be used for determiningproblems in case the RC
system does not function properly:
1. StudySGVoperation manual.
2. Visuallycheck all air hoses and connections to ensure that there are no air leaks.
3. Ensure that the safetyand drain valve are closed.

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Version 2.5
4. Check the RChandle for air leaks:
— whenthe keyis not depressed, the air should comeonlyout of thebodyvent.
— when the keyis depressed no air should come out of the handle.
Problem Cause Solution
Air does not come out
of the vent in the RC
handle body.
Twinline hose is clogged or
pinched. Disconnect the Twinline hose and ensure that it is not
clogged.
Control valve RCVdoes
not open. Safetydrain valve is still open. Close the safetydrain valve.
Air feed to abrasive
blastingmachine is not
sufÀcient.
Dismantle the control valve, all
parts should rotate freely.
RCcontrol valve RCV
does not close. RChandle channels are clogged. Remove the keyand clean it.
Incorrect connection of
TWINLINEhose. Check connections and change them if theyare incorrect.
Control valve failure. Disassemble the valve and
ensure that it functions
properly.

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CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
7. SpeciÀcation.
Fig. 7.1.
Pos.
#
Order
code Description Quantity
DBS-100RCS DBS-200RCS
1 10900
Hose coupling, CFT
2 2
210911
Nipple 1 1/ 4” (MM), rubberized
6 6
310930
Oil-Moisture separator, CAF-3
1 1
410970
Remote control unit RCV
1 1
510915
Union with a cap nut, straight , 1 1/4”, (FM)
3 2
610909
Elbow, 90° , 1 1/ 4” (FM)
1 1
10910
T-piece, 90°, 1 1/ 4”, (FFF)
1 1
810942
Ball valve, 1 1/4”, (MM)
1 1
910913
Union with a cap nut, straight , 1 1/4”, (FF)
1 1

14 CONTRACOR
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Version 2.5
10 10992
Pipe 1 1/4”, (MM) 190 mm for DBS-100RCS/ DBS-200RCS
1—
10991
Pipe 1 1/4”, (MM) 420 mm for DBS-200RCS
—1
11 10916
Elbow, 45° , 1 1/ 4” (FF)
1 1
12 10992
Pipe 1 1/4”, (MM) 190 mm for DBS-100RCS/ DBS-200RCS
1 1
13 10919
Elbow, 45° , 1 1/ 4” (FM)
1 1
14 10948
T-piece, 90° ,1 1/4”, (FFF), rubberized
1 1
15 10949
Threaded Áange 1 1/4” for SGVvalve
1 1
16 10946
SGVmeteringvalve
1 1
17 10994
Pipe 1”, (MM) 190 mm for DBS-100
1—
10952
Pipe 1”, (MM) 260 mm for DBS-200
—1
18 10953
Elbow 90° , 1”, (FF)
1 1
19 10993
Pipe 1”, (M) 165 mm for DBS-100
1—
10954
Pipe 1”, (M) 190 mm for DBS-200
—1
20 10955
Guide
1 1
21 10960
Pressurizingvalve
1 1
22 10950
Pressurizingvalveseat
1 1
23 10932
DBStank serviceassembly, kit
1 1
24 10935
Screen
1—
10936
Screen
—1
25 10933
Tank cover
1—
10934
Tank cover
—1
2 10956
Elbow, 90° , 3/4” (MF)
2 2
28 10958
Pipe 3/4”
1 1
29 10957
Union with a cap nut, straight, 3/4” (FF)
1 1
30 10947
Rubber pipe for SGVvalve
1 1
31 10828
RCBall valve, 1/4”
2 2
33 10922
Wheel
2 —
10923
Wheel
— 2
34 10830
Extension for DBS-100 RC/RCS
1—
10844
Extension for DBS-200 RC/RCS
—1

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CONTRACOR
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DBS-100 RCS, DBS-200RCSArt. 10406/10411
8. Instr ctions for Use Press re Vessel
of Abrasive Blasting Machine
CONTRACOR DBS.
8.1. Technical Parameters.
Vessel Type DBS– 100 -10 DBS– 200 -10
Volume V(L) 100 200
Calculated Pressure P(MPa) 1,0 1,0
Maximum WorkingPres-
sure PS(Bar) 10 10
Maximum Test Pressure PT(bar) 14,3 14,3
Minimal OperatingTempe-
rature TSmin (°C) -10 -10
Maximum OperatingTem-
perature TSmax(°C) 50 50
Corrosion charge c
2
(mm) 0,5 0,5
Media air + abrasive ma-
terials air + abrasive ma- terials
8.2. Field of Application.
The pressure vessels are intended for use onlywith the media and within the parame-
ters stated in the table above. The use for anyother purpose is not allowed.

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Version 2.5
8.3. Set Up and Installation.
1. The vesselscan be set up indoorsor outdoorsunder a roof.
Safety-regulations and standards and Àre-regulations and standards, depending on
the media used, must be observed when choosinga place for setup.When set up
outdoors, the minimal and maximum working temperatures must be observed.
2. The vessels have to be installed in such a waythat theyand all Àttings and parts are
accessible for inspections, tests, maintenance and cleaning, from the inside and the
outside.
The type platehasto beaccessible and kept clean sothat it is readableat all times.
3. The main bodyis based on supports, stands or feet suitable for the strain of the
pressure test. The vessel must be set up on foundations with a stability suitable for
the strain of the pressure test.
8.4. Setting the Vessel to Work.
A. Conditions for setting the vessel to work.
1. The vessel can be set to work, including test operation, if:
— its condition doesnot posea danger to people and environment,
— the system and equipment is complete, tested and meets the requirements
accordingto the documentation and applyingstandards.
B. Proced re before start p of the machine
2. Before closingthe vessel make sure that there is no foreign matter or object inside.
3. Make sure that all inspection doors and Áanges have the correct number of bolts,
that the bolts areinserted correctlyin place and of the right length and tightened to
the correct torque.

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CONTRACOR
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DBS-100 RCS, DBS-200RCSArt. 10406/10411
C. Start p Proced re.
4. If not stated otherwise in the instructions for the start up of the vessel, the control
valve must open in such a waythat the pressure does not rise more than 5 bar per
minute and the temperature does not exceed the value stated for the start up of the
vessel. Avoid sudden changes in pressure or temperature as theycan cause unfavou-
rable tension.
5. Always watch the vessel, valvesand Àttings duringthe start up of the system. If a
problem occurs, e.g. leaks or cracks, the vessel has to be closed down immediately.
6. During transport vessels must not be under pressure and they must not contain
media.
7. When the workingpressure is built up, check the vessel and its attachments for
leaks.
D. Operation of the vessels.
8. The vessel must be closed down immediately,
— if cracks appear,
— if there is aleak in a connection that can bedisassembled,
— if there is a safety-equipment failureor defect (e.g. cloggingof thesafetyvalve)
or a failure of the level meter etc.,
— whenthere is immediatedanger of an accident or a problem if operationconti-
nue,
— if anyother unusual phenomena occur duringoperation whose causes cannot
befound or eliminated,
— if a deformation on the vessel wall occurs,
— if the temperature exceeds the maximum working temperature,
— in all cases stated in the manual that advise the operator to do so.

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Version 2.5
8.5. Operating the Vessel.
1. Onlypersons meetingthe followingrequirements are allowed to operate the vessel:
— The person is of age and able to do such work,
— The person knows the applyingregulations and rules for the operation of the
vessel well, has been trained practicallyand haspassed a correspondingexam
which is documented bya certiÀcate.
A. D ties and responsibilities of the operator
2. The person appointed to operate the vessel is obliged to:
— know all facilitiesand equipment securinga safe operation, and their use, well
and be able to react appropriatelyin unusual circumstances to restore safety,
— report everyproblem, damage or unusual incidents, occurring duringoperation
of the vessel or its attachments,to his superior immediatelyand close down the
vessel if further operation could be dangerous,
— take part in checks and inspections of the vessel, sothat he knows the conditi-
on of the vessel,
— check and test theequipment asrecommended,
— document the operation accordingto the regulations,
B. Vessel Inspections and Tests
3. The vessels have to be subjected to the followingtests and inspections:
— External inspection duringoperation,
— Inspection of interior,
— Leak test,
— Pressure test ,
The tests must be conducted accordingto the applying regulations for the use
of pressure equipment of the respective countrythat the vessel is used in.

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CONTRACOR
®
DBS-100 RCS, DBS-200RCSArt. 10406/10411
C. Doc mentation of Inspections.
4. The resultsof theinspections and tests are recorded in an inspectionlog, Àlled in on
inspection cards or an inspection-certiÀcate is written. The inspection log has to be
kept with the user and available during the whole period of use of the vessel.
8.6. Cleaning and Maintenance of Vessels.
1. The cleaningmethod and media have to be in such a waythat theydonot to damage
the wallsof thevessel or endanger the workers.
2. The vessel must be cleaned inside and outside and it must be covered with a suitable
layer of paint that protects it from inÁuences of the operatingmedia and external
inÁuences.
3. Onlyspeciallytrained and experienced persons are allowed to work on the vessel and
the system components, including the safetyequipment. Theyhave to be appointed
with their namesput down and theyhave to know the regulations in this Àeld of work.
8.7. Repair of Vessels.
It is not allowed to weld or work on the parts of the vessel that are subject to pressu-
re. Onlyauthorized organizations are allowed to install or repair the vessels.

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Version 2.5
ACHTUNG!
BITTE LESEN SIE DIESES HANDBUCH VOR GEBRAUCH DER MASCHINE
GENAU DURCH:
DIE FOLGENDEN INFORMATIONEN SIND WICHTIG FÜR DIE SICHERHEIT
UND GESUNDHEIT DES ANWENDERS UND PERSONEN, DIE SICH IN DER
NÄHE AUFHALTEN.
ACHTUNG!
ACHTEN SIE BEIM KAUF DER MASCHINE BITTE DARAUF, DASS DIE
GARANTIEKARTE VOLLSTÄNDIG AUSGEFÜLLT WIRD.
WENN DIE KARTE NICHT AUSGEFÜLLT VORLIEGT, BESTEHT KEIN
GARANTIEANSPRUCH.
Inhalt
1. Sicherheit 21
2. Ansicht Arbeitsaufbau 22
3. Aufbau, Betrieb und Beenden der Arbeit 24
4. Durchführung von Strahlarbeiten 26
5. Wartung 28
6. Fehlerbehebung 29
7. SpeziÀkation 31
8. Bedienungsanleitungder Druckbehälter des Strahlgerätes CO TRACOR DBS 33