Contracor DBS-100 User manual

CONTRACOR GmbH
42329 Wuppertal
Germany
Art. 10100/10200
Abrasive Blasting Machines
USER MANUAL
Version 2.0
Sandstrahlmaschinen
BEDIENUNGSANLEITUNG
Version 2.0
Seite 18.
Аппараты
абразивоструйные
РУКОВОДСТВО
ПОЛЬЗОВАТЕЛЯ
Версия 2.0
стр. 36.
РУССКИЙ
DEUTSCHENGLISH
DBS-100
DBS-200

2CONTRACOR® Version 2.0
ENGLISH
Contents
1. Safety 3
2. General view 4
3. Set-up, operation and shut-down 6
4. Maintenance and Troubleshooting 8
5. General Drawing 10
6. Instructions for Use Pressure Vessel of
Abrasive Blasting Machine
CONTRACOR DBS 12
7. Warranty and
Warranty Service Regulations 16
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® DBS Art. 10100/10200
ENGLISH
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 2.0
ENGLISH
2. General view.

5
CONTRACOR® DBS Art. 10100/10200
ENGLISH
Fig. 2.1.
1 — cover,
2 — screen,
3 — machine tank,
4 — pressurizing ball valve,
5 — upper air line ball valve,
6 — moisture and oil separator
CAF-1,
7 — lower air line ball valve,
8 — abrasive blasting hose
UNIFLEX,
9 — COMFORT Operator Helmet,
10 — nozzle holder,
11 — nozzle,
12 — breathing air hose,
13 — breathing air lter BAF-1,
Table. 2.1.
Order code Model Description, conguration
10100 DBS-100 Abrasive Blasting Machine, 100 l,
screen,
cover,
lter, oil and moisture separator CAF-1,
abrasive ow control valve FSV.
10200 DBS-200 Abrasive Blasting Machine, 200 l,
screen,
cover,
lter, oil and moisture separator CAF-1,
abrasive ow control valve FSV.

6CONTRACOR® Version 2.0
ENGLISH
3. Set-up, operation and shut-down.
3.1. Preparation for operation.
1. Ensure that compressor is positioned out of the abrasive blasting operation zone on
downwind side.
2. Start compressor and increase pressure and temperature up to operational values.
3. Open lower ball valve at machine compressed air line (the handle of the open valve
should be parallel to the compressed air line).
4. Open the tank venting ball valve.
5. Close compressed air feed ball valve (upper ball valve on the compressed air line).
6. Close metering valve FSV by setting adjusting handle in the central position.
7. Connect compressed air hose to coupling of the machine. Compressed air hose
diameter should be at least 1.25”. Lock hose coupling with a safety clip or wire.
8. Connect abrasive blasting hose to hose coupling of the machine. Lock hose coupling
with a safety clip or wire.
9. Fill the machine tank with abrasive.
10. Put protective equipment on.

7
CONTRACOR® DBS Art. 10100/10200
ENGLISH
3.2. Abrasive blasting operations.
1. Feed compressed air to the machine inlet.
ATTENTION!
MACHINE MAXIMUM OPERATING PRESSURE — 12bar.
2. Close the pressurizing ball valve.
3. Upon the signal of the abrasive blasting operator open the ball valve and feed
compressed air into the machine line. The tank is pressurized. Only compressed air is
expelled from the nozzle.
4. Adjust metering valve FSV to provide optimal air-abrasive mixture. The general rule for
abrasive blasting operations: the less abrasive you use, the better.
5. To stop operation close the compressed air feed ball valve and immediately open the
pressurizing ball valve to relieve pressure in the tank.
3.3. Abrasive blasting operation shut-down.
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. Close the
pressurizing ball valve and open compressed air feed ball valve.
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.

8CONTRACOR® Version 2.0
ENGLISH
4. Maintenance and Troubleshooting.
4.1. 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 rmly to correct position.
ATTENTIION!
USE ONLY ABRASIVE MATERIALS, APPROPRIATE FOR ABRASIVE BLASTING
OPERATIONS.
NEVER USE WET UNSIFTED ABRASIVE MATERIALS.
4.2. Troubleshooting.
Clogging.
If neither abrasive, nor air comes out of the nozzle, relieve pressure and depressurize
the machine, then ensure that the nozzle is not clogged. 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, if 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

9
CONTRACOR® DBS Art. 10100/10200
ENGLISH
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.

10 CONTRACOR® Version 2.0
ENGLISH
5. General Drawing.
No Order
No Description Q-ty
DBS-100 DBS-200
1 10900 Hose coupling, CFT 2 2
2 10911 Nipple 1 1/4” (MM), rubberized 4 4
3 10930 Oil-Moisture separator, CAF-3 1 1
5 10915 Union with cap nut, straight, 1 ”, (FM) 2 1
6 10909 Elbow, 90°, 1 ” (FM) 1 1
7 10910 T-piece, 90°, 1 ”, (FFF) 1 1
8 10942 Ball valve, 1 ”, (MM) 2 2
9 10913 Union with a cap nut, straight , 1 ”, (ММ) — 1
10 10914 Pipe 1 1/4” — 1
11 10916 Elbow, 45°, 1 1/4” (ММ) 1 1
12 10917 Pipe 1 1/4” 1 1
13 10919 Elbow, 45°, 1 1/4” (FM) 1 1
14 10990 Y-piece, 45°, 1 1/4”, (FFF), rubberized 1 1
15 10921 Pipe 1 1/4”, (100mm), rubberized 1 1
16 10920 Metering gate valve, FSV 1 1
17 10952 Pipe 1” 1 1
18 10953 Elbow 90°, 1”, (ММ) 1 1
19 10954 Pipe 1” 1 1
20 10955 Guide 1 1
21 10960 Pressurizing valve 1 1
22 10950 Pressurizing valve seat 1 1
23 10932 DBS tank service assembly, kit 1 1
24 10935 Screen 1 —
24 10936 Screen — 1
25 10933 Tank cover 1 —
25 10934 Tank cover — 1
33 10922 Wheel 2 —
33 10923 Wheel — 2
34 10941 Elbow, 90°, 1”, (FM) 2 2
35 10938 Ball valve, 1” (MF) 1 1

11
CONTRACOR® DBS Art. 10100/10200
ENGLISH
Fig. 5.1.

12 CONTRACOR® Version 2.0
ENGLISH
6. Instructions for Use Pressure Vessel
of Abrasive Blasting Machine
CONTRACOR DBS.
6.1. Technical Parameters.
Vessel Type DBS – 100 - 10 DBS – 200 - 10
Manufacturing Date 2007 2007
Volume V (L) 100 200
Calculated Pressure P (MPa) 1,0 1,0
Maximum Working Pres-
sure
PS (Bar) 10 10
Maximum Test Pressure PT (bar) 14,3 14,3
Minimal Operating Tempe-
rature
TSmin (°C) -10 -10
Maximum Operating Tem-
perature
TSmax (°C) 50 50
Corrosion charge c2 (mm) 0,5 0,5
Media air + abrasive ma-
terials
air + abrasive ma-
terials
Number of notify category 1433 1433
Danger Class III III
Module F F
6.2. Field of Application.
The pressure vessels are intended for use only with the media and within the parame-
ters stated in the table above. The use for any other purpose is not allowed.

13
CONTRACOR® DBS Art. 10100/10200
ENGLISH
6.3. Set Up and Installation.
1. The vessels can be set up indoors or outdoors under a roof.
Safety-regulations and standards and re-regulations and standards, depending on
the media used, must be observed when choosing a 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 way that they and all ttings and parts are
accessible for inspections, tests, maintenance and cleaning, from the inside and the
outside.
The type plate has to be accessible and kept clean so that it is readable at all times.
3. The main body is 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.
6.4. 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 does not pose a danger to people and environment,
— the system and equipment is complete, tested and meets the requirements
according to the documentation and applying standards.
B. Procedure before start up of the machine
2. Before closing the vessel make sure that there is no foreign matter or object inside.
3. Make sure that all inspection doors and anges have the correct number of bolts,
that the bolts are inserted correctly in place and of the right length and tightened to
the correct torque.

14 CONTRACOR® Version 2.0
ENGLISH
C. Start up Procedure.
4. If not stated otherwise in the instructions for the start up of the vessel, the control
valve must open in such a way that 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 they can cause unfavou-
rable tension.
5. Always watch the vessel, valves and ttings during the 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 working pressure 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 a leak in a connection that can be disassembled,
— if there is a safety-equipment failure or defect (e.g. clogging of the safety valve)
or a failure of the level meter etc.,
— when there is immediate danger of an accident or a problem if operation conti-
nue,
— if any other unusual phenomena occur during operation whose causes cannot
be found 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.

15
CONTRACOR® DBS Art. 10100/10200
ENGLISH
6.5. Operating the Vessel.
1. Only persons meeting the following requirements are allowed to operate the vessel:
— The person is of age and able to do such work,
— The person knows the applying regulations and rules for the operation of the
vessel well, has been trained practically and has passed a corresponding exam
which is documented by a certicate.
A. Duties and responsibilities of the operator
2. The person appointed to operate the vessel is obliged to:
— know all facilities and equipment securing a safe operation, and their use, well
and be able to react appropriately in unusual circumstances to restore safety,
— report every problem, damage or unusual incidents, occurring during operation
of the vessel or its attachments, to his superior immediately and close down the
vessel if further operation could be dangerous,
— take part in checks and inspections of the vessel, so that he knows the conditi-
on of the vessel,
— check and test the equipment as recommended,
— document the operation according to the regulations,
B. Vessel Inspections and Tests
3. The vessels have to be subjected to the following tests and inspections:
— External inspection during operation,
— Inspection of interior,
— Leak test,
— Pressure test ,
The tests must be conducted according to the applying regulations for the use
of pressure equipment of the respective country that the vessel is used in.

16 CONTRACOR® Version 2.0
ENGLISH
C. Documentation of Inspections.
4. The results of the inspections and tests are recorded in an inspection log, lled in on
inspection cards or an inspection-certicate is written. The inspection log has to be
kept with the user and available during the whole period of use of the vessel.
6.6. Cleaning and Maintenance of Vessels.
1. The cleaning method and media have to be in such a way that they do not to damage
the walls of the vessel 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 inuences of the operating media and external
inuences.
3. Only specially trained and experienced persons are allowed to work on the vessel and
the system components, including the safety equipment. They have to be appointed
with their names put down and they have to know the regulations in this eld of work.
6.7. Repair of Vessels.
It is not allowed to weld or work on the parts of the vessel that are subject to pressu-
re. Only authorized organizations are allowed to install or repair the vessels.
7. Warranty and
Warranty Service Regulations.
Please, ensure that this warranty card is lled in clearly, correctly with completely by
the seller organization, that sells you our product.
1. CONTRACOR warrants production (hereinafter referred to as “equipment”)
manufactured by CONTRACOR to be free from defects in workmanship preventing normal
equipment operation during twelve months. This period of time is calculated from the date
of purchase lled in by the Seller organization (hereinafter referred to as “Seller”) in this
warranty policy.

17
CONTRACOR® DBS Art. 10100/10200
ENGLISH
2. Obligations arising from this warranty are fullled by the Seller or authorized organi-
zations. Please contact the Seller to obtain the list of authorized organizations.
3. This warranty is limited to the repair or replacement of the defective part only, the
defect of the part appeared during the period of warranty, without any payments by the
purchaser if conditions of the warranty are observed. Repair or replacement of defect parts
will not extend the warranty coverage on the equipment beyond the original expiration date.
4. Above-mentioned warranty term does not apply to assemblies and parts if in the
user’s guide supplied with the equipment a special warranty term is specied for these as-
semblies and details.
5. This warranty is not applied to the defects, caused by improper use or use with
violation of intended use, wrong storage, drops or impacts, incorrect maintenance, damage
caused by freezing or use with violation of user’s manual requirements.
6. The warranty does not cover electric motor damage caused by one phase failure.
7. The warranty does not apply to the equipment with external mechanical defects.
8. This warranty does not cover consumable materials and the parts, which service
life depends on operation conditions: lters, high pressure and rubber hoses, nozzles,
spray-guns, seals, quick-release couplings, tip holders etc.
9. Natural wear and tear of equipment, caused by its operation with intensity incon-
sistent with that specied in user’s manual and equipment function, is not covered by this
warranty.
10. Defects resulted from usage of the devices, accessories or consumable materials
other than offered by the equipment supplier, and in case of equipment modication not
approved by the manufacturer or unauthorized repair of the equipment are not covered by
this warranty.
11. Equipment shipment for warranty repair and a technician trip to the site of the
repair are produced at the buyer’s expense.
12. This warranty is given to the representative of the organization that purchased the
equipment and can not be transferred to another individual or organization.
13. The Seller disclaims liability for potential harm, directly or indirectly caused to
people or property in case this resulted from violation of the operation procedures, whether
intended or negligent by the purchaser or third parties.
14. Liability for any special, consequential or incidental damages (including but not
limited to loss of revenue or prot, downtime costs, loss of the use of the equipment, re-
gardless of cause or for breach of any written or implied warranty is expressly disclaimed.

DEUTSCH
18 CONTRACOR® Version 2.0
Inhalt
1. Sicherheit 19
2. Ansicht Arbeitsaufbau 20
3. Aufbau, Betrieb undBeenden der Arbeit 22
4. Wartung und Fehlerbehebung 24
5. Übersichtszeichnung 26
6. Bedienungsanleitungder Druckbehälter
des Strahlgerätes CONTRACOR DBS 28
7. Garantie und Garantiebedingungen 33
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.

DEUTSCH
19
CONTRACOR® DBS Art. 10100/10200
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.

DEUTSCH
20 CONTRACOR® Version 2.0
2. Ansicht Arbeitsaufbau.