Contracor BlastRazor Z-100RCS User manual

CONTRACOR GmbH
42327 Wuppertal,
Germany Art. 10400102/10400202
Abrasive Blasting Machines
BlastRazor Z-100RCS, BlastRazor Z-200RCS
OPERATION MANUAL
Version 1.5
EN
DE
Sandstrahlmaschinen
BlastRazor Z-100RCS
BlastRazor Z-200RCS
BEDIENUNGSANLEITUNG
Version 1.5
Seite 16
RU
Аппараты абразивоструйные
BlastRazor Z-100RCS
BlastRazor Z-200RCS
РУКОВОДСТВО ПО ЭКСПЛУАТАЦИИ
Версия 1.5
стр. 30
STEEL COLOR TECHNOLOGY, s.r.o.
Trieda A. Hlinku 21
949 01 Nitra
Kamenná predajňa:
LEHOTA 706
951 36 Lehota
0905 933 247
[email protected]
www.est.sk
www.99.inshop.sk

2CONTRACOR®Version 1.5
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. Specication 13
ATTENTION!
READ AND FULLY UNDERSTAND THIS MANUAL BEFORE STARTING WORK.
THE FOLLOWING INFORMATION IS IMPORTANT FOR SAFETY AND HEALTH OF
OPERATOR AND PERSONNEL IN VICINITY.
ATTENTION!
BUYING THE MACHINE, PLEASE, REQUEST TO FILL IN THE GUARANTEE CARD
CORRECTLY!
FAILURE TO PRODUCE A FILLED-IN FORM WILL MAKE YOUR GUARANTEE
INVALID.

3
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
1. Safety.
ATTENTION!
SAFETY MEASURES FOR ABRASIVE BLASTING.
1. You must wear protective equipment: a helmet with positive
air feed, breathing air lter, protection suit, leather 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 ttings are not worn;
— Fix hose couplings with wire;
— Ensure that air is fed to the helmet;
— Ensure that pressurizing valve is in correct position;
— Ensure that the machine is in steady state position

4CONTRACOR®Version 1.5
2. Package and description.
Fig. 2.1.
8
2
13
14
4
5
1
3
6
7
9
11
10
12

5
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
Fig. 2.1.
1 — cover
2 — screen
3 — machine tank
4 — RC hose
5 — Remote control unit
6 — moisture and oil separator
7 — abrasive blasting hose
8 — operator helmet
9 — nozzle holder
10 — nozzle
11 — RC handle
12 — breathing air hose
13 — breath air lter
14 — safety ball valve
2.1. Package.
Table. 2.1.
Order code Model Description, package
10400102 BlastRazor-
100RCS
Abrasive Blasting Machine, 100 L,
screen,
cover,
moisture and oil separator lter CAF-1,
remote control unit RCV,
remote control handle DMH,
metering valve SGV,
twin hose in RC TWINLINE 20m,
tting set for RC hose.
10400202 BlastRazor-
200RCS
Abrasive Blasting Machine, 200l,
screen, cover,
moisture and oil separator lter CAF-1,
remote control unit RCV,
remote control handle DMH,
metering valve SGV,
RC twin hose TWINLINE 20m,
tting set for RC hose.
10110870 RCV Remote control valve (5, Fig.2.1)
10110880 DMH Remote control handle (11, Fig.2.1)
10112106 TWINLINE Remote control twin hose, d=6mm, roll 40 m
(4, Fig.2.1)

6CONTRACOR®Version 1.5
3. Set-up, operation and shut-down.
3.1. Preparation for operation.
For remote control system start up you should follow these instructions:
1. If necessary shorten the RC hose to the length of the used blasting hose.
2. Connect the ttings provided in the package with RC hose. Connect RC hose to
distant control handle DMH from one side and TWINLINE line of the blasting machine
from another side.
ATTENTION!
DO NOT TIGHTEN UNIONS TOO MUCH, IN PARTICULAR THE UNIONS OF RC
HANDLE. IT CAN DAMAGE SOME COMPONENTS AND CAUSE AN AIR LEAK.
3. Ensure that all connections are leak-proof.
4. Ensure that all connections on the RC valve and RC handle DMH are connected
properly, and according to the color. Transverse joint will make the system non-
operational.
5. Fix RC handle DMH to the blasting hose, using clamp bands right behind the nozzle holder.
6. We recommend to connect a twin hose Twinline to the blasting hose using clamp
bands every 1.5 m.
ATTENTION!
ALWAYS USE AN OIL-MOISTURE SEPARATOR WHEN USING REMOTE
CONTROL SYSTEM TO PREVENT WEAR ON RC VALVE.
BESIDES, AN OIL-MOISTURE SEPARATOR OPTIMIZES ABRASIVE BLASTING
OPERATIONS.
7. Ensure that compressor is positioned out of the abrasive blasting operations zone on
downwind side.
8. Start compressor and increase pressure and temperature up to operational values.

7
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
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 safety ball valve 14 (Fig.2.1).
11. Close metering valve SGV by rotating the handle clockwise.
12. Connect compressed air hose to hose coupling of the machine. Compressed air hose
diameter should be at least 1.1/4". Lock hose coupling with a safety clip or wire.
13. Connect abrasive blasting hose to hose coupling of the machine. Lock hose coupling
with a safety clip or wire.
14. Fill the machine tank with abrasive.
15. Put protective equipment on.

8CONTRACOR®Version 1.5
4. Abrasive blasting operations.
4.1. Start up.
1. Check all connections from compressor to the nozzle to ensure that they are properly
xed (badly xed air hose of the compressor cause a serious damage).
2. Ensure that abrasive blasting machine is lled with abrasive.
3. Ensure that the necessary safety measures for you and others are observed:
— protective equipment is used,
— puried air is fed to the helmet.
4. Always check position of RC handle lever, which should be in the safety position with
the holder in vertical position
5. Feed compressed air to the machine intake.
ATTENTION!
MACHINE MAXIMUM OPERATING PRESSURE — 10 bar.
6. Close both ball valves at the RC valve.
7. Ensure that there is no leak in the system. Air should come ONLY out of the vent
under the RC handle lever.

9
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
4.2. Abrasive blasting operations.
ATTENTION!
DURING A BREAK IN OPERATION ALWAYS OPEN SAFETY BALL VALVE 14 (Fig.
2.1) AT RC VALVE, OVER AGAINST THE BLUE LINE OF TWIN HOSE (TWINLINE).
RC HANDLE LEVER SHOULD BE NEVER FIXED IN OPERATION POSITION.
SUCH FIXING MAY CAUSE A SERIOUS INJURE.
1. Turn the holder on RC handle and press the lever (start up). The tank is pressurized.
Only compressed air is expelled from the nozzle.
2. Adjust metering valve SGV to 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 automatically returns 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 RC handle and press the lever.
2. If upon completion of operation the machine is left outside you should cover it with
plastic lm to avoid ingress of moisture into the tank.
ATTENTION!
AT START UP AND SHUT DOWN ALWAYS CHECK FOR PRESENCE OF WATER
IN THE SGV VALVE BY OPENING THE UPPER BALL VALVE (Fig. 7.1). IF A
LARGE AMOUNT OF WATER IS PRESENT, CHECK THE FILTER CAF-3.

10 CONTRACOR®Version 1.5
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 new valve and screw the guide tube back into
its place.
Pressurizing valve ring replacement.
The ring is replaced trough the machine lling orice. Pull out the old ring, put a new ring
into the groove and press it heavily to correct position.
ATTENTION!
USE ONLY ABRASIVE MATERIALS, APPROPRIATE FOR ABRASIVE BLASTING
OPERATIONS.
NEVER USE WET UNSIFTED ABRASIVE MATERIALS.
5.2. Daily maintenance.
1. Check the control valve for water presence. If water is present, check the CAF-3 lter
state.
2. Ensure that the rubber insert of the RC handle is in proper condition. If they look bad
or are worn, replace them, to avoid possible damage.
3. Ensure that hoses and ttings are not worn; and properly xed.
5.3. Monthly maintenance (or after every 160 operation hours).
1. Ensure that the mufer and its pipe are in proper condition.
2. Ensure that there is no leak in all air connections.
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.

11
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
6. Troubleshooting.
Choking.
If neither abrasive, nor air comes out of the nozzle, relieve pressure and depressurize the
machine, then ensure that the nozzle is not choked. If only air without any abrasive comes
out of the nozzle, fully open the metering valve, and then quickly close 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.
During start-up of the machine abrasive surges are normal to a certain degree. However
id abrasive surges continue, you should stabilize the abrasive ow by quick closing and
opening of the line lower ball valve. Abrasive surges often result from elevated moisture
content in compressed air system. Installation of 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 machine hose coupling. Then you must fully open the metering
valve and close the lower ball valve in the machine compressed air line. With such valve
conguration compressed air will only enter the machine tank and press wet abrasive out of
the tank.
6.1. RC system troubleshooting.
The following list of checks can be used for determining problems in case the RC system
does not function properly:
1. Study SGV operation manual.
2. Visually check all air hoses and connections to ensure that there are no air leaks.
3. Ensure that the safety and drain valve are closed.
4. Check the RC handle for air leaks:
— when the key is not depressed, the air should come only out of the body vent.
— when the key is depressed no air should come out of the handle.

12 CONTRACOR®Version 1.5
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 RCV does
not open.
Safety drain valve is still
open.
Close the safety drain valve.
Air feed to abrasive
blasting machine is not
sufcient.
Dismantle the control valve, all
parts should rotate freely.
RC control valve RCV
does not close.
RC handle channels are
clogged.
Remove the key and clean it.
Incorrect connection of
TWINLINE hose.
Check connections and change
them if they are incorrect.
Control valve failure. Disassemble the valve and
ensure that it functions
properly.

13
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
7. Specication.
Fig. 7.1.
No Article Description Q-ty
BlastRazor
Z-100RCS
BlastRazor
Z-200RCS
1 80900016 Pressure vessel 1 -
80900017 Pressure vessel - 1
2 88200003 Screen 1 -
88200004 Screen - 1
1
2
3
4
4
5
6 7
89
10
11
12
14
15
16
17
18
19 21
22
23
23
24
25
26
27
28
29
30
30
31
32
32
32
33
34
35
36
37
38
39
40
41
42
43
20
44
45
46
46
46
47
47
48
48
48
48
32 21
13
49

14 CONTRACOR®Version 1.5
3 81100058 Cover 1 -
81100059 Cover - 1
4 80500031 Threaded ange 2 2
5 10110955 Guide 1 1
6 81600024 Pipe 1 -
81600026 Pipe - 1
7 73025126 Pipe 1 -
73025136 Pipe - 1
8 73120044 Pipe 1 1
9 73120125 Pipe 1 1
10 73120155 Pipe 1 1
11 73132230 Pipe 1 -
73132450 Pipe - 1
12 73132152 Pipe 1 -
73132238 Pipe - 1
13 52150002 Handhole, set 1 1
14 10110950 O-Ring 1 1
15 10110960 Pressurizing valve 1 1
16 10110870 Remote control valve RCV, assy. with silenser 1 1
17 10110930 Moisture separator CAF-3 1 1
18 10110860 Metering valve SGV 1 1
19 10110948 T-piece, rubberized 1 1
20 10110911 Nipple, rubberized 1 1
21 10110900 Hose coupling CFT 2 2
22 52080002 Elbow 1 1
23 10110956 Elbow 2 2
24 10110909 Elbow 1 1
25 10110951 Elbow 1 1
26 10110953 Elbow 1 1
27 10110919 Elbow 1 1
28 10110916 Elbow 1 1
29 10110957 Union 1 1
30 10110915 Union 2 2
31 10110840 Nipple 1 1
32 10110924 Nipple 4 4
33 10110910 T-piece 1 1
34 52120006 Lock nut 1 1
35 10110942 Ball valve 1 1
36 10110828 Ball valve 1 1

15
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
37 28300005 Wheel 2 -
28300006 Wheel - 2
38 64110022 Washer 2 -
64110026 Washer - 2
39 60210440 Safety splint 2 2
40 61111040 Screw 8 8
41 63110010 Nut 8 8
42 64310010 Washer 8 8
43 64110010 Washer 8 8
44 10110880 Handle DMH 1 1
45 10112401 Fitting 2 2
46 10112402 Fitting 6 6
47 10112106 Twinline hose 20 м 20 м
48 90100005 Hose clamp 8 8
48 52150003 Rubber gasket 1 1

16 CONTRACOR®Version 1.5
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 17
2. Ansicht Arbeitsaufbau 18
3. Aufbau, Betrieb und Beenden der Arbeit 20
4. Durchführung von Strahlarbeiten 22
5. Wartung 24
6. Fehlerbehebung 25
7. Spezikation 27

17
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
1. Sicherheit.
ACHTUNG!
SICHERHEITSREGELN FÜR STRAHLARBEITEN.
1. Tragen Sie Schutzausrüstung: einen Strahlhelm mit
Frischluftzufuhr und Atemluftlter, einen Schutzanzug,
Lederhandschuhe, und spezielles Schuhwerk.
2. Benutzen Sie keine abgenutzte oder beschädigte Ausrüstung.
3. Richten Sie die Düse nur auf den zu bearbeitenden Bereich.
4. Verwenden Sie nur geeignete, trockene und gut
durchgesiebte Strahlmaterialien.
5. Alle Personen ohne Schutzausrüstung müssen außerhalb des
Arbeitsbereiches bleiben.
6. Bevor Sie mit der Strahlarbeit beginnen, müssen Sie
folgendes beachten:
—Stellen Sie sicher, dass Schläuche und Verbindungen
unbeschädigt und nicht abgenutzt sind;
—Sichern Sie Schlauchkupplungen mit Sicherungsstift
oder Draht;
—Überprüfen Sie die Luftzufuhr des Helmes;
—Stellen Sie sicher, dass das Kesseldruckventil richtig
eingestellt ist;
—Überprüfen Sie den festen und sicheren Stand der
Maschine.

18 CONTRACOR®Version 1.5
2. Ansicht Arbeitsaufbau.
Abb. 2.1.
8
2
13
14
4
5
1
3
6
7
9
11
10
12

19
CONTRACOR® BlastRazor Z-100 RCS/ BlastRazor Z-200 RCS Art.10400102/10400202
Abb. 2.1.
1 — Deckel
2 — Sieb
3 — Kessel
4 — Fernbedienungsschlauch
5 — Fernbedienungsventil
6 — Wasserabscheider
7 — Strahlschlauch
8 — Strahlhelm
9 — Düsenhalter
10 — Düse
11 — Fernbedienung
12 — Atemluftschlauch
13 — Atemluftlter
14 — Unterbrecherkugelventil
2.1. Beschreibung.
Tabelle 2.1.
Bestellnummer Modell Beschreibung, Lieferumfang
10400102 BlastRazor-
100RCS
Strahlmaschine, 100 l,
Sieb,
Deckel ,
Wasserabscheider CAF-3,
Fernbedienungsventil RCV,
Fernbedienungshebel DMH,
Dosierventil für metallische Strahlmittel SGV,
Doppelschlauch RC TWINLINE 20 m,
Anschluss-Set für Fernbedienungsschlauch.
10400202 BlastRazor-
200RCS
Strahlmaschine, 200 l,
Sieb, Deckel,
Wasserabscheider CAF-3,
Fernbedienungsventil RCV,
Fernbedienungshebel DMH,
Dosierventil für metallische Strahlmittel SGV,
Doppelschlauch TWINLINE 20 m,
Anschluss-Set für Fernbedienungsschlauch.
10110870 RCV Fernbedienungsventil (5, Abb. 2.1)
10110880 DMH Fernbedienungshebel (11, Abb. 2.1)
10112106 TWINLINE Doppelschlauch für Fernbedienung, d=6mm, Rolle
40 m (4, Abb.2.1)

20 CONTRACOR®Version 1.5
3. Aufbau, Betrieb und
Beenden der Arbeit.
3.1. Arbeitsvorbereitung.
Zur Inbetriebnahme des Fernbedienungssystems sollten Sie folgende Schritte einhalten:
1. Falls notwendig, kürzen Sie den Fernbedienungsschlauch auf die Länge des
verwendeten Strahlschlauches.
2. Bringen Sie die mitgelieferten Anschlussstücke an dem Fernbedienungsschlauch
TWINLINE an. Schließen Sie dann das eine Schlauchende am Fernbedienungshebel
DMH und das andere an der Strahlmaschine an.
ACHTUNG!
ZIEHEN SIE DIE VERBINDUNGEN NICHT ZU FEST AN, INSBESONDERE DIE
AN DER FERNBEDIENUNG, DA SIE SONST BESCHÄDIGT UND UNDICHT
WERDEN KÖNNTEN.
3. Bitte überprüfen Sie, ob alle Verbindungen leckfrei sind.
4. Stellen Sie sicher, dass alle Verbindungen an der Fernbedienung DMH und
dem Fernbedienungsventil richtig und den Farbmarkierungen entsprechend
angeschlossen sind. Bei vertauschten Anschlüssen funktioniert das System nicht.
5. Befestigen Sie die Fernbedienung DMH direkt hinter dem Düsenhalter mit
Schlauchschellen am Strahlschlauch.
6. Wir empfehlen, den Twinline-Schlauch alle 1,5 m mit Schlauchschellen am
Strahlschlauch zu befestigen.
ACHTUNG!
BENUTZEN SIE IMMER EINEN WASSERABSCHEIDER MIT IHREM
FERNBEDIENUNGSSYSTEM, UM DAS VENTIL VOR ÜBERMÄSSIGER
ABNUTZUNG ZU SCHÜTZEN.
EIN ABSCHEIDER WIRKT SICH AUSSERDEM POSITIV AUF DIE DIE
STRAHLARBEIT AUS.